MA KR QUANTEC-2 en

Robots KR QUANTEC-2 With F and C Variants Assembly Instructions Issued: 21.08.2023 MA KR QUANTEC-2 V11 KUKA Deutschland GmbH KR QUANTEC-2 © Copyright 2023 KUKA Deutschland GmbH Zugspitzstraße 140 D-86165 Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Deutschland GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. KIM-PS5-DOC Translation of the original documentation Publication: Pub MA KR QUANTEC-2 (PDF) en PB11438 Book structure: MA KR QUANTEC-2 V10.1 BS10356 Version: 2/651 | www.kuka.com MA KR QUANTEC-2 V11 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Contents 1 Introduction.............................................................................................. 13 1.1 1.2 1.3 1.4 Target group.......................................................................................................... Industrial robot documentation.............................................................................. Representation of warnings and notes................................................................. Terms used............................................................................................................ 13 13 13 14 2 Product description................................................................................. 19 2.1 2.2 2.3 Overview of the robot system............................................................................... Description of the manipulator.............................................................................. Intended use and misuse...................................................................................... 19 20 23 3 Safety......................................................................................................... 25 3.1 3.1.1 3.1.2 3.1.3 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 General.................................................................................................................. Disclaimer.............................................................................................................. EC declaration of conformity and declaration of incorporation............................ Terms in the “Safety” chapter............................................................................... Personnel............................................................................................................... Workspace, safety zone and danger zone........................................................... Overview of protective equipment........................................................................ Mechanical end stops........................................................................................... Mechanical axis limitation (optional)..................................................................... Options for moving the manipulator without drive energy................................... Labeling on the industrial robot............................................................................ Safety measures.................................................................................................... General safety measures...................................................................................... Transportation........................................................................................................ Start-up and recommissioning.............................................................................. Manual mode......................................................................................................... Automatic mode..................................................................................................... Maintenance and repair........................................................................................ Decommissioning, storage and disposal.............................................................. 25 25 26 26 28 29 29 29 30 30 31 31 31 33 33 35 36 36 38 4 Technical data.......................................................................................... 39 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.4 4.4.1 4.4.2 Technical data, overview....................................................................................... Technical data, KR 120 R2700-2.......................................................................... Basic data, KR 120 R2700-2................................................................................ Axis data, KR 120 R2700-2.................................................................................. Payloads, KR 120 R2700-2.................................................................................. Foundation loads, KR 120 R2700-2..................................................................... Technical data, KR 120 R2700-2 F...................................................................... Basic data, KR 120 R2700-2 F............................................................................ Axis data, KR 120 R2700-2 F.............................................................................. Payloads, KR 120 R2700-2 F............................................................................... Foundation loads, KR 120 R2700-2 F................................................................. Technical data, KR 120 R3100-2.......................................................................... Basic data, KR 120 R3100-2................................................................................ Axis data, KR 120 R3100-2.................................................................................. 39 43 43 45 48 54 56 56 58 61 67 69 69 71 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 3/651 KR QUANTEC-2 4.4.3 4.4.4 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.10 4.10.1 4.10.2 4.10.3 4.10.4 4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.12 4.12.1 4.12.2 4.12.3 4.12.4 4.13 4.13.1 4.13.2 4.13.3 4.13.4 4.14 4.14.1 Payloads, KR 120 R3100-2.................................................................................. Foundation loads, KR 120 R3100-2..................................................................... Technical data, KR 120 R3100-2 F...................................................................... Basic data, KR 120 R3100-2 F............................................................................ Axis data, KR 120 R3100-2 F.............................................................................. Payloads, KR 120 R3100-2 F............................................................................... Foundation loads, KR 120 R3100-2 F................................................................. Technical data, KR 150 R2700-2.......................................................................... Basic data, KR 150 R2700-2................................................................................ Axis data, KR 150 R2700-2.................................................................................. Payloads, KR 150 R2700-2.................................................................................. Foundation loads, KR 150 R2700-2..................................................................... Technical data, KR 150 R2700-2 F...................................................................... Basic data, KR 150 R2700-2 F............................................................................ Axis data, KR 150 R2700-2 F.............................................................................. Payloads, KR 150 R2700-2 F............................................................................... Foundation loads, KR 150 R2700-2 F................................................................. Technical data, KR 150 R3100-2.......................................................................... Basic data, KR 150 R3100-2................................................................................ Axis data, KR 150 R3100-2.................................................................................. Payloads, KR 150 R3100-2.................................................................................. Foundation loads, KR 150 R3100-2..................................................................... Technical data, KR 150 R3100-2 F...................................................................... Basic data, KR 150 R3100-2 F............................................................................ Axis data, KR 150 R3100-2 F.............................................................................. Payloads, KR 150 R3100-2 F............................................................................... Foundation loads, KR 150 R3100-2 F................................................................. Technical data, KR 180 R2900-2.......................................................................... Basic data, KR 180 R2900-2................................................................................ Axis data, KR 180 R2900-2.................................................................................. Payloads, KR 180 R2900-2.................................................................................. Foundation loads, KR 180 R2900-2..................................................................... Technical data, KR 180 R2900-2 F...................................................................... Basic data, KR 180 R2900-2 F............................................................................ Axis data, KR 180 R2900-2 F.............................................................................. Payloads, KR 180 R2900-2 F............................................................................... Foundation loads, KR 180 R2900-2 F................................................................. Technical data, KR 210 R2700-2.......................................................................... Basic data, KR 210 R2700-2................................................................................ Axis data, KR 210 R2700-2.................................................................................. Payloads, KR 210 R2700-2.................................................................................. Foundation loads, KR 210 R2700-2..................................................................... Technical data, KR 210 R2700-2 F...................................................................... Basic data, KR 210 R2700-2 F............................................................................ Axis data, KR 210 R2700-2 F.............................................................................. Payloads, KR 210 R2700-2 F............................................................................... Foundation loads, KR 210 R2700-2 F................................................................. Technical data, KR 210 R3100-2.......................................................................... Basic data, KR 210 R3100-2................................................................................ 4/651 | www.kuka.com 73 79 81 81 83 85 91 93 93 95 98 104 106 106 108 111 117 119 119 121 123 129 131 131 133 135 141 143 143 145 148 154 156 156 158 161 167 169 169 171 174 180 182 182 184 187 193 195 195 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 4.14.2 4.14.3 4.14.4 4.15 4.15.1 4.15.2 4.15.3 4.15.4 4.16 4.16.1 4.16.2 4.16.3 4.16.4 4.17 4.17.1 4.17.2 4.17.3 4.17.4 4.18 4.18.1 4.18.2 4.18.3 4.18.4 4.19 4.19.1 4.19.2 4.19.3 4.19.4 4.20 4.20.1 4.20.2 4.20.3 4.20.4 4.21 4.21.1 4.21.2 4.21.3 4.21.4 4.22 4.22.1 4.22.2 4.22.3 4.22.4 4.23 4.23.1 4.23.2 4.23.3 4.23.4 4.24 Axis data, KR 210 R3100-2.................................................................................. Payloads, KR 210 R3100-2.................................................................................. Foundation loads, KR 210 R3100-2..................................................................... Technical data, KR 210 R3100-2 F...................................................................... Basic data, KR 210 R3100-2 F............................................................................ Axis data, KR 210 R3100-2 F.............................................................................. Payloads, KR 210 R3100-2 F............................................................................... Foundation loads, KR 210 R3100-2 F................................................................. Technical data, KR 210 R3100-2 C...................................................................... Basic data, KR 210 R3100-2 C............................................................................ Axis data, KR 210 R3100-2 C.............................................................................. Payloads, KR 210 R3100-2 C.............................................................................. Foundation loads, KR 210 R3100-2 C................................................................. Technical data, KR 240 R2900-2.......................................................................... Basic data, KR 240 R2900-2................................................................................ Axis data, KR 240 R2900-2.................................................................................. Payloads, KR 240 R2900-2.................................................................................. Foundation loads, KR 240 R2900-2..................................................................... Technical data, KR 240 R2900-2 F...................................................................... Basic data, KR 240 R2900-2 F............................................................................ Axis data, KR 240 R2900-2 F.............................................................................. Payloads, KR 240 R2900-2 F............................................................................... Foundation loads, KR 240 R2900-2 F................................................................. Technical data, KR 240 R2900-2 C...................................................................... Basic data, KR 240 R2900-2 C............................................................................ Axis data, KR 240 R2900-2 C.............................................................................. Payloads, KR 240 R2900-2 C.............................................................................. Foundation loads, KR 240 R2900-2 C................................................................. Technical data, KR 250 R2700-2.......................................................................... Basic data, KR 250 R2700-2................................................................................ Axis data, KR 250 R2700-2.................................................................................. Payloads, KR 250 R2700-2.................................................................................. Foundation loads, KR 250 R2700-2..................................................................... Technical data, KR 250 R2700-2 F...................................................................... Basic data, KR 250 R2700-2 F............................................................................ Axis data, KR 250 R2700-2 F.............................................................................. Payloads, KR 250 R2700-2 F............................................................................... Foundation loads, KR 250 R2700-2 F................................................................. Technical data, KR 250 R2700-2 C...................................................................... Basic data, KR 250 R2700-2 C............................................................................ Axis data, KR 250 R2700-2 C.............................................................................. Payloads, KR 250 R2700-2 C.............................................................................. Foundation loads, KR 250 R2700-2 C................................................................. Technical data, KR 300 R2700-2.......................................................................... Basic data, KR 300 R2700-2................................................................................ Axis data, KR 300 R2700-2.................................................................................. Payloads, KR 300 R2700-2.................................................................................. Foundation loads, KR 300 R2700-2..................................................................... Technical data, KR 300 R2700-2 F...................................................................... MA KR QUANTEC-2 V11 | Issued: 21.08.2023 197 199 205 207 207 209 211 217 219 219 221 223 229 231 231 233 236 242 244 244 246 249 255 257 257 259 262 268 270 270 272 275 281 283 283 285 288 294 296 296 298 301 307 309 309 311 314 320 322 www.kuka.com | 5/651 KR QUANTEC-2 4.24.1 4.24.2 4.24.3 4.24.4 4.25 4.25.1 4.25.2 4.25.3 4.25.4 4.26 4.27 4.28 4.28.1 4.28.2 4.28.2.1 4.28.2.2 4.28.2.3 4.28.2.4 4.28.3 4.28.3.1 4.28.3.2 4.28.3.3 4.28.3.4 4.28.4 4.28.4.1 4.28.4.2 4.28.4.3 4.28.4.4 4.28.5 4.28.5.1 4.28.5.2 4.28.5.3 4.28.5.4 4.28.6 4.28.6.1 4.28.6.2 4.28.6.3 4.28.6.4 4.28.7 4.28.7.1 4.28.7.2 4.28.7.3 4.28.7.4 4.28.8 4.28.8.1 4.28.8.2 4.28.8.3 4.28.8.4 Basic data, KR 300 R2700-2 F............................................................................ Axis data, KR 300 R2700-2 F.............................................................................. Payloads, KR 300 R2700-2 F............................................................................... Foundation loads, KR 300 R2700-2 F................................................................. Technical data, KR 300 R2700-2 C...................................................................... Basic data, KR 300 R2700-2 C............................................................................ Axis data, KR 300 R2700-2 C.............................................................................. Payloads, KR 300 R2700-2 C.............................................................................. Foundation loads, KR 300 R2700-2 C................................................................. Plates and labels................................................................................................... REACH duty to communicate information acc. to Art. 33................................... Stopping distances and times............................................................................... General information............................................................................................... Stopping distances and times, KR 120 R2700-2 and KR 120 R2700-2 F......... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 120 R3100-2 and KR 120 R3100-2 F......... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 150 R2700-2 and KR 150 R2700-2 F......... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 150 R3100-2 and KR 150 R3100-2 F......... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 180 R2900-2 and KR 180 R2900-2 F......... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 210 R2700-2 and KR 210 R2700-2 F......... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 210 R3100-2, KR 210 R3100-2 F and KR 210 R3100-2 C...................................................................................................... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... 6/651 | www.kuka.com 322 324 327 333 335 335 337 340 346 348 352 352 352 354 354 355 357 359 359 359 361 363 365 365 365 367 369 371 371 371 373 375 377 377 377 379 381 383 383 383 385 387 389 389 389 391 393 395 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 4.28.9 4.28.11.1 4.28.11.2 4.28.11.3 4.28.11.4 Stopping distances and times, KR 240 R2900-2, KR 240 R2900-2 F and KR 240 R2900-2 C...................................................................................................... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 250 R2700-2, KR 250 R2700-2 F and KR 250 R2700-2 C...................................................................................................... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... Stopping distances and times, KR 300 R2700-2, KR 300 R2700-2 F and KR 300 R2700-2 C...................................................................................................... Stopping distances and stopping times, STOP 0, A1 to A3............................... Stopping distances and stopping times, STOP 1, A1.......................................... Stopping distances and stopping times, STOP 1, A2.......................................... Stopping distances and stopping times, STOP 1, A3.......................................... 407 407 409 411 413 5 Planning.................................................................................................... 415 5.1 5.2 5.3 5.4 5.5 Information for planning........................................................................................ Mounting base with centering............................................................................... Mounting base 150 mm (optional)........................................................................ Machine frame mounting....................................................................................... Connecting cables and interfaces......................................................................... 415 415 418 421 423 6 Transportation.......................................................................................... 427 6.1 Transporting the robot........................................................................................... 427 7 Start-up and recommissioning............................................................... 433 7.1 7.1.1 7.1.2 7.1.3 7.2 7.2.1 7.2.2 7.2.3 7.3 7.3.1 7.3.2 7.3.3 7.4 7.4.1 7.4.2 7.4.3 7.5 7.5.1 7.5.2 7.5.3 Starting up floor-mounted robots (mounting base).............................................. Installing the robot with mounting base................................................................ Connecting the connecting cables........................................................................ Concluding work.................................................................................................... Starting up floor-mounted robots (optional 150 mm mounting base).................. Installing the robot with mounting base 150 mm (optional)................................. Connecting the connecting cables........................................................................ Concluding work.................................................................................................... Starting up robots (machine frame mounting)...................................................... Installing the robot with the machine frame mounting assembly........................ Connecting the connecting cables........................................................................ Concluding work.................................................................................................... Description of the connecting cables, KR C4...................................................... Description of the Motor cable.............................................................................. Description of the Data cable............................................................................... Description of the ground conductor.................................................................... Description of the connecting cables, KR C5...................................................... Description of the Motor cable.............................................................................. Description of the Data cable............................................................................... Description of the ground conductor.................................................................... 4.28.9.1 4.28.9.2 4.28.9.3 4.28.9.4 4.28.10 4.28.10.1 4.28.10.2 4.28.10.3 4.28.10.4 4.28.11 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 395 395 397 399 401 401 401 403 405 407 433 435 437 437 438 440 442 442 443 445 446 447 447 448 450 451 451 452 454 455 www.kuka.com | 7/651 KR QUANTEC-2 8 Maintenance.............................................................................................. 457 8.1 8.1.1 8.2 8.2.1 8.2.2 8.2.3 8.3 8.3.1 8.3.2 8.3.3 8.4 8.4.1 8.4.2 8.4.3 8.5 8.5.1 8.5.2 8.5.3 8.6 8.6.1 8.6.2 8.6.3 8.7 8.7.1 8.7.2 8.7.3 8.8 8.8.1 8.8.2 8.9 8.9.1 8.9.2 8.9.3 8.9.4 8.9.5 8.9.6 8.10 8.10.1 8.10.2 8.10.3 8.10.4 8.10.5 8.10.6 8.11 8.11.1 8.11.2 Maintenance overview........................................................................................... Maintenance table................................................................................................. Oil change in A1, floor-mounted robot................................................................. Draining the gear oil from A1............................................................................... Filling A1 with gear oil.......................................................................................... Concluding work.................................................................................................... Oil change in A1, ceiling-mounted robot.............................................................. Draining the gear oil from A1............................................................................... Filling gear unit A1 with gear oil........................................................................... Concluding work.................................................................................................... Oil change in A2................................................................................................... Draining the gear oil from A2............................................................................... Filling A2 with gear oil.......................................................................................... Concluding work.................................................................................................... Oil change in A3................................................................................................... Draining the gear oil from A3............................................................................... Filling gear unit A3 with gear oil........................................................................... Concluding work.................................................................................................... Oil change in A4................................................................................................... Draining the gear oil from A4............................................................................... Filling gear unit A4 with gear oil........................................................................... Concluding work.................................................................................................... Oil change in A5/A6.............................................................................................. Draining the gear oil on A5/A6............................................................................. Filling gear unit A5/A6 with gear oil..................................................................... Concluding work.................................................................................................... Checking the counterbalancing system................................................................ Checking the counterbalancing system................................................................ Concluding work.................................................................................................... Counterbalancing system, floor, exchanging........................................................ Securing the link arm............................................................................................ Removing the counterbalancing system on a floor-mounted robot..................... Installing the counterbalancing system................................................................. Removing the equipment securing the link arm.................................................. Checking the counterbalancing system................................................................ Concluding work.................................................................................................... Exchanging the counterbalancing system on a ceiling-mounted robot............... Securing the link arm............................................................................................ Removing the counterbalancing system on a ceiling-mounted robot.................. Installing the counterbalancing system on a ceiling-mounted robot.................... Removing the equipment securing the link arm.................................................. Checking the counterbalancing system................................................................ Concluding work.................................................................................................... Cleaning the robot................................................................................................. Cleaning................................................................................................................. Concluding work.................................................................................................... 8/651 | www.kuka.com 457 458 461 463 463 464 464 466 467 468 468 470 471 472 472 474 475 476 476 478 479 480 480 482 484 485 485 486 487 487 489 490 493 496 497 497 498 500 500 503 505 506 507 507 508 508 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 9 Repair........................................................................................................ 509 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.5 9.5.1 9.5.2 9.5.3 9.5.4 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6 9.6.7 9.6.8 9.6.9 9.6.10 9.7 9.7.1 9.7.2 9.7.3 9.7.4 9.7.5 9.7.6 Exchanging motor A1............................................................................................ Removing motor A1.............................................................................................. Preparing a new motor for installation................................................................. Installing motor A1................................................................................................ Concluding work.................................................................................................... Exchanging motor A2............................................................................................ Securing the link arm............................................................................................ Removing motor A2.............................................................................................. Preparing a new motor for installation................................................................. Installing motor A2................................................................................................ Removing the equipment securing the link arm.................................................. Concluding work.................................................................................................... Exchanging motor A3............................................................................................ Securing the robot arm......................................................................................... Removing motor A3.............................................................................................. Preparing a new motor for installation................................................................. Installing motor A3................................................................................................ Removing the equipment securing the robot arm................................................ Concluding work.................................................................................................... Exchanging motor A4............................................................................................ Removing motor A4.............................................................................................. Preparing the new motor A4 - A5 for installation................................................ Installing motor A4................................................................................................ Concluding work.................................................................................................... Exchanging motor A5............................................................................................ Removing motor A5.............................................................................................. Preparing the new motor A4 - A5 for installation................................................ Installing motor A5................................................................................................ Concluding work.................................................................................................... Exchanging motor A6............................................................................................ Removing motor A4.............................................................................................. Removing motor A5.............................................................................................. Removing the in-line wrist..................................................................................... Removing motor A6.............................................................................................. Preparing a new motor for installation................................................................. Installing motor A6................................................................................................ Installing the in-line wrist....................................................................................... Installing motor A5................................................................................................ Installing motor A4................................................................................................ Concluding work.................................................................................................... Exchanging the in-line wrist.................................................................................. Removing motor A4.............................................................................................. Removing motor A5.............................................................................................. Removing the in-line wrist..................................................................................... Removing motor A6.............................................................................................. Preparing the new in-line wrist............................................................................. Installing motor A6................................................................................................ 509 511 512 513 514 514 517 518 519 520 521 522 522 525 526 528 529 531 532 532 535 536 537 539 539 542 544 545 547 547 550 552 554 556 556 557 558 560 562 563 564 566 568 570 572 572 573 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 9/651 KR QUANTEC-2 9.7.7 9.7.8 9.7.9 9.7.10 9.8 9.8.1 9.8.2 9.8.3 9.8.4 9.8.5 9.8.6 9.9 Installing the in-line wrist....................................................................................... Installing motor A5................................................................................................ Installing motor A4................................................................................................ Concluding work.................................................................................................... Exchanging the connecting shafts........................................................................ Removing motor A4.............................................................................................. Removing motor A5.............................................................................................. Preparing the new connecting shafts................................................................... Installing motor A5................................................................................................ Installing motor A4................................................................................................ Concluding work.................................................................................................... Description of the electrical installations.............................................................. 574 575 577 579 579 582 583 585 585 587 589 589 10 Decommissioning, storage and disposal............................................. 601 10.1 10.1.1 10.1.2 10.1.3 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.3 Decommissioning................................................................................................... Moving the robot into its transport position.......................................................... Removing the robot............................................................................................... Concluding work.................................................................................................... Storage.................................................................................................................. Moving the robot into its transport position.......................................................... Removing the robot............................................................................................... Cleaning................................................................................................................. Preparing for storage............................................................................................ Concluding work.................................................................................................... Disposal................................................................................................................. 601 601 602 603 603 604 605 606 606 607 607 11 Options...................................................................................................... 609 11.1 11.1.1 11.1.1.1 11.1.1.2 11.1.1.3 11.2 11.2.1 11.2.1.1 11.2.1.2 11.2.2 11.2.2.1 11.2.2.2 11.3 11.3.1 11.3.1.1 11.3.1.2 11.3.2 11.3.2.1 11.3.2.2 11.4 11.5 11.6 Release device...................................................................................................... Starting up the release device.............................................................................. Installing the release device................................................................................. Moving the manipulator without drive energy...................................................... Concluding work.................................................................................................... Cover of hollow shaft A1...................................................................................... Putting the cover for hollow shaft A1 into operation........................................... Installing the cover of hollow shaft A1................................................................. Concluding work.................................................................................................... Cleaning the cover of hollow shaft A1................................................................. Cleaning the cover of hollow shaft A1................................................................. Concluding work.................................................................................................... Cable set cover .................................................................................................... Starting up the cable set cover............................................................................ Installing the cable set cover................................................................................ Concluding work.................................................................................................... Cleaning the cover of hollow shaft A1................................................................. Cleaning the cover of hollow shaft A1................................................................. Concluding work.................................................................................................... Purge option A...................................................................................................... Purge option B...................................................................................................... Purge option C...................................................................................................... 10/651 | www.kuka.com 609 610 611 612 613 613 614 615 617 617 617 618 618 620 620 623 624 624 624 625 626 627 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 11.6.1 11.6.1.1 11.6.1.2 11.7 11.7.1 11.7.1.1 11.7.1.2 Starting up PURGE option C................................................................................ Installing PURGE option C................................................................................... Concluding work.................................................................................................... Purge option D...................................................................................................... Starting up PURGE option D................................................................................ Installing PURGE option D................................................................................... Concluding work.................................................................................................... 629 629 630 630 632 632 633 12 Appendix................................................................................................... 635 12.1 12.2 12.3 12.4 Tightening torques................................................................................................. Auxiliary and operating materials used................................................................ Information sheet for products.............................................................................. Applied standards and regulations....................................................................... 635 636 637 643 13 KUKA Service........................................................................................... 645 13.1 13.2 Requesting support............................................................................................... KUKA Customer Support...................................................................................... 645 645 Index 647 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 11/651 KR QUANTEC-2 12/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 1 Introduction 1.1 Target group Introduction KR QUANTEC-2 This documentation is aimed at users with the following knowledge and skills: • Advanced knowledge of mechanical engineering • Advanced knowledge of electrical engineering • Knowledge of the robot controller system For optimal use of KUKA products, we recommend the training courses offered by KUKA College. Information about the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries. 1.2 Industrial robot documentation The industrial robot documentation consists of the following parts: • • • • • • Documentation for the robot arm Documentation for the robot controller Documentation for the smartPAD-2 or smartPAD pro (if used) Documentation for the System Software Instructions for options and accessories Spare parts overview in KUKA Xpert Each set of instructions is a separate document. 1.3 Representation of warnings and notes Safety These warnings are provided for safety purposes and must be observed. DANGER These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions are taken. WARNING These warnings mean that death or severe injuries may occur, if no precautions are taken. CAUTION These warnings mean that minor injuries may occur, if no precautions are taken. NOTICE These warnings mean that damage to property may occur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 13/651 KR QUANTEC-2 Introduction This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: SAFETY INSTRUCTION The following procedure must be followed exactly! Procedures marked with this warning must be followed exactly. Notices These notices serve to make your work easier or contain references to further information. Tip to make your work easier or reference to further information. 1.4 Terms used The overview may contain terms symbols that are not relevant for this document. Term Description Axis range Range within which the axis may move The axis range must be defined for each axis. Stopping distance Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. Workspace Area within which the robot may move. The workspace is derived from the individual axis ranges. Arctic Arctic for use in temperature ranges under 0° C (273 K). Extension Distance (l in %) between axis 1 and the intersection of axes 4 and 5. With parallelogram robots, the distance between axis 1 and the intersection of axis 6 and the mounting flange. C Ceiling CR Clean Room Designation for KUKA products developed for use in cleanrooms. EDS Electronic Data Storage (memory card) EDS cool Electronic Data Storage cool Memory card with extended temperature range 14/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Introduction KR QUANTEC-2 EMD Electronic Mastering Device SPP Spare parts package EX Explosion-proof zone F Foundry F exclusive Foundry exclusive Danger zone The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). HA High Accuracy HI High Inertia HM Hygienic Machine For the primary and secondary foodstuffs industries HO Hygienic Oil For the secondary foodstuffs industry HP High Protection HW Hollow Wrist K Shelf-mounted KCP KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. KR KUKA robot KR C KUKA Robot Control Robot controller KS Shelf-mounted, small KUKA smartPAD see “smartPAD” KUKA smartPAD-2 see “smartPAD” Manipulator The robot arm and the associated electrical installations MEMD Micro Electronic Mastering Device micro RDC micro Resolver Digital Converter MT Machine Tooling P Press-to-press robot PA Palletizer Phi Angle of rotation (°) about the corresponding axis. This value can be entered in the controller via the teach pendant, from which it can be read. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 15/651 Introduction KR QUANTEC-2 POV Program override (%) = velocity of the robot motion. This value can be entered in the controller via the teach pendant, from which it can be read. RDC Resolver Digital Converter The resolver digital converter is used to acquire motor data (e.g. position data, motor temperatures). RDC cool Resolver Digital Converter Resolver Digital Converter with extended temperature range SC Special Connection SE Second Encoder SI Safe Interaction SL Washdown smartPAD Teach pendant for the robot controller The smartPAD has all the operator control and display functions required for operation and programming. The following models exist: • KUKA smartPAD • KUKA smartPAD-2 • KUKA smartPAD pro For robot controllers of the KR C5 series with KUKA System Software or VW System Software, only the model KUKA smartPAD-2 is used. For robot controllers of the KR C5 series with KUKA iiQKA.OS, only the model KUKA smartPAD pro is used. For other robot controllers, the designation “KUKA smartPAD” or “smartPAD” always refers to all models possible for the respective controller unless an explicit distinction is made. Stop categories Note: Information about the stop categories for KUKA robot controllers can be found in the “Safety” chapter of the robot controller assembly instructions. T1 Test mode, Manual Reduced Velocity (<= 250 mm/s) For KUKA iiQKA.OS: With manual guidance in T1, the velocity is not reduced, but rather limited through a safety-oriented velocity monitoring in accordance with the safety configuration. T2 For KUKA iiQKA.OS: not relevant at present For KUKA System Software / VW System Software: Test mode, Manual High Velocity (> 250 mm/s permissible) W Wall WP Waterproof 16/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 External axis For KUKA iiQKA.OS: not relevant at present For KUKA System Software / VW System Software: Axis of motion that does not belong to the manipulator, yet is controlled with the robot controller. For example, KUKA linear unit, turntilt table and positioner MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 17/651 Introduction KR QUANTEC-2 Introduction KR QUANTEC-2 18/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 2 Product description 2.1 Overview of the robot system A robot system (>>> Fig. 2-1) comprises all the assemblies of an industrial robot, including the manipulator (mechanical system and electrical installations), robot controller, connecting cables, tool and other equipment. The KR QUANTEC-2 product family comprises the following robot types: • • • • • • • • • • • • • • • • • • • • • • • • KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR 120 120 120 120 150 150 150 150 180 180 210 210 210 210 210 240 240 240 250 250 250 300 300 300 R2700-2 R2700-2 R3100-2 R3100-2 R2700-2 R2700-2 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R3100-2 R3100-2 R3100-2 R2900-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 R2700-2 R2700-2 F F F F F F F C F C F C F C An industrial robot of this product family comprises the following components: • • • • • • Manipulator Robot controller Connecting cables Teach pendant (KUKA smartPAD) Software Options, accessories MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 19/651 Product description KR QUANTEC-2 Product description KR QUANTEC-2 Fig. 2-1: Example of an industrial robot 2.2 1 Manipulator 3 Robot controller 2 Connecting cables 4 smartPAD Description of the manipulator Overview The manipulators (= robot arm and electrical installations) of the variants are designed as 6-axis jointed-arm kinematic systems. They consist of the following main assemblies: • • • • • • • 20/651 | www.kuka.com In-line wrist Arm Link arm Counterbalancing system Rotating column Base frame Electrical installations MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Product description KR QUANTEC-2 Fig. 2-2: Main assemblies of the manipulator 1 In-line wrist 5 Base frame 2 Arm 6 Rotating column 3 Counterbalancing system 7 Link arm 4 Electrical installations DANGER Axes 1 to 3 are equipped with end stops. These serve to protect the machine only. The following options are available for personnel protection: • The Safe Robot functionality of the controller • The use of mechanical axis limitations for axes 1 to 3 (optional) In-line wrist The robot is fitted with a 3-axis in-line wrist. The in-line wrist contains axes 4, 5 and 6. The motor of axis 6 is located directly on the wrist, inside the arm. It drives the wrist directly, while for axes 4 and 5 the drive comes from the rear of the arm via connecting shafts. For attaching end effectors (tools), the in-line wrist has a mounting flange. Arm The arm is the link between the in-line wrist and the link arm. It houses the motors of wrist axes 4 and 5. The arm is driven by the motor of axis 3. The maximum permissible swivel angle is mechanically limited by an overrun safeguard for each direction, plus and minus. There is an interface on the arm for fastening supplementary loads. Link arm The link arm is the assembly located between the arm and the rotating column. The maximum permissible swivel angle is mechanically limited by an overrun safeguard for each direction, plus and minus. There is an interface on the link arm for fastening supplementary loads. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 21/651 Product description KR QUANTEC-2 Rotating column The rotating column houses the motors of axes 1 and 2. The rotational motion of axis 1 is performed by the rotating column. The rotating column also supports the link arm. The bearings of the counterbalancing system are situated at the rear. There is also an interface for fastening supplementary loads on the rotating column. Base frame The base frame is the base of the robot. It is screwed to the mounting base. The electrical installations are fastened in the base frame. Also located on the base frame is the interface for the motor and data cable and the energy supply system. Counterbalancing system The counterbalancing system is installed between the rotating column and the link arm and serves to minimize the moments generated about axis 2 when the robot is in motion and at rest. A closed, hydropneumatic system is used. The system consists of two accumulators, a hydraulic cylinder with associated hoses, a pressure gauge and a bursting disc as a safety element to protect against overfilling. The counterbalancing system is classified below category I, fluid group 2, of the Pressure Equipment Directive. Electrical installations The electrical installations include all the motor and data cables for the motors of axes 1 to 6. All connections are implemented as plug-in connectors in order to enable the motors to be exchanged quickly and reliably. The electrical installations also include the RDC box, which is mounted on the rotating column. The interface on the base frame of the robot for connecting the connecting cables has plug-and-socket connections. The connecting cables from the robot controller can be plugged in by means of connectors. The electrical installations also include an integrated protective circuit. Options The robot can, for example, be equipped with the following options. The option is described in separate documentation. • • • • • • • • Axis limitations for axes A1, A2 and A3 Energy supply systems A1 to A3 Energy supply systems A3 to A6 Booster Frame S780 Mounting flange (adapter) Mounting flange (adapter) in corrosion-protected design Adapter ring KR QUANTEC/KR QUANTEC-2 Brake release device The following options are also available: • Release device (>>> 11.1 "Release device" Page 609) • Cover on hollow shaft A1 (>>> 11.2 "Cover of hollow shaft A1" Page 613) • Cable set cover (>>> 11.3 "Cable set cover " Page 618) • Purge option A (>>> 11.4 "Purge option A" Page 625) • Purge option B (>>> 11.5 "Purge option B" Page 626) • Purge option C (>>> 11.6 "Purge option C" Page 627) 22/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 • Purge option D (>>> 11.7 "Purge option D" Page 630) 2.3 Intended use and misuse Intended use The industrial robot is intended for handling tools and fixtures or for processing and transferring components or products. Use is only permitted under the specified environmental conditions. Operation of the industrial robot in accordance with its intended use also requires compliance with the operating and assembly instructions for the individual components, with particular reference to the maintenance specifications. Misuse Any use or application deviating from the intended use is deemed to be misuse and is not allowed. It will result in the loss of warranty and liability claims. KUKA is not liable for any damage resulting from such misuse. This includes e.g.: • • • • • • • • Use as a climbing aid Operation outside the specified operating parameters Operation without the required safety equipment Transportation of persons and animals Outdoor operation. Use in a potentially explosive area Use in radioactive environments Operation in underground mining NOTICE Deviations from the operating conditions specified in the technical data or the use of special functions or applications can lead to premature wear, for example. KUKA Service must be consulted in this event. The robot system is an integral part of a complete system and may only be operated in a CE-compliant system. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 23/651 Product description KR QUANTEC-2 Product description KR QUANTEC-2 24/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 3 Safety 3.1 General Safety KR QUANTEC-2 • This “Safety” chapter refers to a mechanical component of an industrial robot. • If the mechanical component is used together with a KUKA robot controller, the “Safety” chapter of the operating instructions or assembly instructions of the robot controller must be used! This contains all the information provided in this “Safety” chapter. It also contains additional safety information relating to the robot controller which must be observed. • Where this “Safety” chapter uses the term “industrial robot”, this also refers to the individual mechanical component if applicable. 3.1.1 Disclaimer The device described in this document is either an industrial robot or a component thereof. Components of the industrial robot: • • • • • Manipulator Robot controller Teach pendant Connecting cables External axes (optional) e.g. linear unit, turn-tilt table, positioner • Software • Options, accessories The industrial robot is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life and limb or cause damage to the industrial robot and to other material property. The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the industrial robot is subject to compliance with this document and with the declaration of incorporation supplied together with the industrial robot. Any functional disorders, especially those affecting safety, must be rectified immediately. Safety information Information about safety may not be construed against the manufacturer. Even if all safety instructions are followed, this is not a guarantee that the industrial robot will not cause personal injuries or material damage. No modifications may be carried out to the industrial robot without the authorization of the manufacturer. Unauthorized modifications will result in the loss of warranty and liability claims. Additional components (tools, software, etc.), not supplied by the manufacturer, may be integrated into the industrial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property. In addition to the Safety chapter, this document contains further safety instructions. These must also be observed. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 25/651 Safety KR QUANTEC-2 3.1.2 EC declaration of conformity and declaration of incorporation The industrial robot constitutes partly completed machinery as defined by the EC Machinery Directive. The industrial robot may only be put into operation if the following preconditions are met: • The industrial robot is integrated into a complete system. or: The industrial robot, together with other machinery, constitutes a complete system. or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added to the industrial robot. • The complete system complies with the EC Machinery Directive. This has been confirmed by means of a conformity assessment procedure. EC declaration of conformity The system integrator must issue an EC declaration of conformity for the complete system in accordance with the Machinery Directive. The EC declaration of conformity forms the basis for the CE mark for the system. The industrial robot must always be operated in accordance with the applicable national laws, regulations and standards. The robot controller has a CE mark in accordance with the EMC Directive and the Low Voltage Directive. Declaration of incorporation The partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery is not allowed until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. 3.1.3 Terms in the “Safety” chapter Term Description Axis range Range within which the axis may move The axis range must be defined for each axis. Stopping distance Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. Workspace Area within which the robot may move. The workspace is derived from the individual axis ranges. User The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. 26/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Service life The service life of a safety-relevant component begins at the time of delivery of the component to the customer. The service life is not affected by whether the component is used or not, as safety-relevant components are also subject to aging during storage. Danger zone The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). KCP KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. KUKA smartPAD see “smartPAD” KUKA smartPAD-2 see “smartPAD” Manipulator The robot arm and the associated electrical installations Safety zone The safety zone is situated outside the danger zone. smartPAD Teach pendant for the robot controller The smartPAD has all the operator control and display functions required for operation and programming. The following models exist: • KUKA smartPAD • KUKA smartPAD-2 • KUKA smartPAD pro For robot controllers of the KR C5 series with KUKA System Software or VW System Software, only the model KUKA smartPAD-2 is used. For robot controllers of the KR C5 series with KUKA iiQKA.OS, only the model KUKA smartPAD pro is used. For other robot controllers, the designation “KUKA smartPAD” or “smartPAD” always refers to all models possible for the respective controller unless an explicit distinction is made. Stop categories Note: Information about the stop categories for KUKA robot controllers can be found in the “Safety” chapter of the robot controller assembly instructions. System integrator (plant integrator) The system integrator is responsible for safely integrating the industrial robot into a complete system and commissioning it. T1 Test mode, Manual Reduced Velocity (<= 250 mm/s) For KUKA iiQKA.OS: With manual guidance in T1, the velocity is not reduced, but rather limited through a safety-oriented velocity monitoring in accordance with the safety configuration. T2 For KUKA iiQKA.OS: not relevant at present For KUKA System Software / VW System Software: Test mode, Manual High Velocity (> 250 mm/s permissible) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 27/651 Safety KR QUANTEC-2 Safety KR QUANTEC-2 External axis For KUKA iiQKA.OS: not relevant at present For KUKA System Software / VW System Software: Axis of motion that does not belong to the manipulator, yet is controlled with the robot controller. For example, KUKA linear unit, turntilt table and positioner 3.2 Personnel The following persons or groups of persons are defined for the industrial robot: • User • Personnel Qualification of personnel Work on the system must only be performed by personnel that is able to assess the tasks to be carried out and detect potential hazards. Death, severe injuries or damage to property may otherwise result. The following qualifications are required: • Adequate specialist training, knowledge and experience • Knowledge of the relevant operating or assembly instructions, knowledge of the relevant standards • All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety chapter. User The user must observe the labor laws and regulations. This includes e.g.: • The user must • The user must • The user must tive equipment comply with his monitoring obligations. carry out briefing at defined intervals. comply with the regulations relating to personal protec(PPE). Personnel Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. Personnel includes: • System integrator • Operators, subdivided into: ‒ Start-up, maintenance and service personnel ‒ Operating personnel ‒ Cleaning personnel System integrator The industrial robot is safely integrated into a complete system by the system integrator. The system integrator is responsible for the following tasks: • Installing the industrial robot 28/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 • • • • • • Connecting the industrial robot Performing the risk assessment Implementing the required safety functions and safeguards Issuing the EC declaration of conformity Affixing the CE mark Creating the operating instructions for the system Operators The operator must meet the following preconditions: • The operator must be trained for the work to be carried out. • Work on the system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. 3.3 Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). The danger zone must be protected by means of physical safeguards to prevent danger to persons or the risk of material damage. The safeguards (e.g. safety gate) must be located outside the danger zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. There must be no shearing or crushing hazards at the loading and transfer areas. If there are no physical safeguards present, the requirements for collaborative operation in accordance with EN ISO 10218 must be met. 3.4 Overview of protective equipment The protective equipment of the mechanical component may include: • • • • • Mechanical end stops Mechanical axis limitation (optional) Release device (optional) Brake release device (optional) Labeling of danger areas Not all equipment is relevant for every mechanical component. 3.4.1 Mechanical end stops Depending on the robot variant, the axis ranges of the main and wrist axes of the manipulator are partially limited by mechanical end stops. Additional mechanical end stops can be installed on the external axes. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 29/651 Safety KR QUANTEC-2 Safety KR QUANTEC-2 WARNING Danger to life and limb following collision with obstacle If the manipulator or an external axis hits an obstruction or a mechanical end stop or mechanical axis limitation, the manipulator can no longer be operated safely. Death, injuries or damage to property may result. • Put manipulator out of operation. • Put external axis out of operation. • KUKA must be consulted before they are put back into operation. 3.4.2 Mechanical axis limitation (optional) Some manipulators can be fitted with adjustable mechanical axis limitation systems in axes A1 to A3. The axis limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system. In the case of manipulators that are not designed to be fitted with mechanical axis limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechanical axis limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or mechanical limitations on the system side. There must be no shearing or crushing hazards at the loading and transfer areas. This option is not available for all robot models. Information on specific robot models can be obtained from the manufacturer. 3.4.3 Options for moving the manipulator without drive energy Qualification of personnel with regard to behavior in emergency situations In emergencies or other exceptional situations, it may be necessary to move the manipulator without drive energy. • Personnel must be trained in how to move the manipulator without drive energy. Description The following options may be available for moving the manipulator without drive energy after an accident or malfunction: • Release device (optional) The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive motors. • Brake release device (option) The brake release device is designed for robot variants whose motors are not freely accessible. • Moving the wrist axes directly by hand There is no release device available for the wrist axes of variants in the low payload category. This is not necessary because the wrist axes can be moved directly by hand. Information about the options available for the various robot models and about how to use them can be found in the assembly and operating instructions for the robot or can be requested from the manufacturer. 30/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 3.4.4 Safety KR QUANTEC-2 Labeling on the industrial robot All plates, labels, symbols and marks constitute safety-relevant parts of the industrial robot. They must not be modified or removed. Labeling on the industrial robot consists of: • • • • • • Identification plates Warning signs Safety symbols Designation labels Cable markings Rating plates Further information is contained in the technical data of the operating instructions or assembly instructions of the components of the industrial robot. 3.5 Safety measures 3.5.1 General safety measures The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the industrial robot even after the robot controller has been switched off and locked out. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the manipulator and external axes must be secured by appropriate means. DANGER Risk of fatal injury due to non-operational safety functions or external safeguards In the absence of operational safety functions or safeguards, the industrial robot can cause death, severe injuries or damage to property. • If safety functions or safeguards are dismantled or deactivated, do not operate the industrial robot. DANGER Danger to life and limb of persons under the robot arm Sagging or falling parts can cause death or serious injuries. This applies at all times, e.g. also for assembly tasks or with the controller switched off. • Never loiter under the robot arm. CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cause burns. • Avoid contact. • Take appropriate safety precautions, e.g. wear protective gloves. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 31/651 Safety KR QUANTEC-2 Implants WARNING Danger to life due to malfunction of implants caused by motors and brakes Electric motors and brakes generate electric and magnetic fields. The fields can cause malfunctions in active implants, e.g. pacemakers. • Affected persons must maintain a minimum distance of 300 mm from motors and brakes. This applies to both energized and deenergized motors and brakes. KCP/smartPAD The user must ensure that the industrial robot is only operated with the KCP/smartPAD by authorized persons. If more than one KCP/smartPAD is used in the overall system, it must be ensured that each device is unambiguously assigned to the corresponding industrial robot. They must not be interchanged. WARNING Danger to life due to disconnected smartPAD/KCP If a smartPAD/KCP is disconnected, its EMERGENCY STOP device is not operational. There is a risk of connected and disconnected smartPADs/KCPs being interchanged. Death, injuries or damage to property may result. • Remove the disconnected smartPAD/KCP from the system immediately. • Store the disconnected smartPAD/KCP out of sight and reach of personnel working on the industrial robot. The enabling switches on the smartPAD must be subjected to a function test at least once every 12 months and in certain specific cases. Information about function testing for KUKA robot controllers can be found in the “Safety” chapter of the operating or assembly instructions of the robot controller. External keyboard, external mouse An external keyboard and/or external mouse may only be used if the following conditions are met: • Start-up or maintenance work is being carried out. • The drives are switched off. • There are no persons in the danger zone. The KCP/smartPAD must not be used as long as an external keyboard and/or external mouse are connected to the control cabinet. The external keyboard and/or external mouse must be removed from the control cabinet as soon as the start-up or maintenance work is completed or the KCP/smartPAD is connected. Modifications After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). 32/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes e.g. modifications of the external axes or to the software and configuration settings. Faults In the case of faults on the industrial robot, the following safety measures must be implemented immediately: • Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. • Indicate the fault by means of a label with a corresponding warning (tagout). • Keep a record of the faults. Carry out a functional test after the fault has been rectified. 3.5.2 Transportation Manipulator The prescribed transport position of the manipulator must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot. Avoid vibrations and impacts during transportation in order to prevent damage to the manipulator. Robot controller The prescribed transport position of the robot controller must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot controller. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller. External axis (optional) The prescribed transport position of the external axis (e.g. KUKA linear unit, turn-tilt table, positioner) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis. 3.5.3 Start-up and recommissioning Before starting up systems and devices for the first time, a check must be carried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested. Changing default passwords The system software is supplied with default passwords for the user groups. If the passwords are not changed, this enables unauthorized persons to log on. • Before start-up, change the passwords for the user groups. • Only communicate the passwords to authorized personnel. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 33/651 Safety KR QUANTEC-2 Safety KR QUANTEC-2 WARNING Danger to life and limb due to incorrectly assigned cables The robot controller is preconfigured for the specific industrial robot. The manipulator and other components can receive incorrect data if they are connected to a different robot controller. Death, severe injuries or damage to property may result. • Only connect the manipulator to the corresponding robot controller. Do not impair safety functions Additional components (e.g. cables and hoses) not supplied by KUKA may be integrated into the industrial robot. If the safety functions are not taken into consideration, this may result in death, severe injuries or damage to property. • Additional components must not impair or disable safety functions. NOTICE Damage to property due to condensation If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form. This may result in damage to property. • Wait until the internal cabinet temperature has adapted to the ambient temperature in order to avoid condensation. Function test The following tests must be carried out before start-up and recommissioning: It must be ensured that: • The industrial robot is correctly installed and fastened in accordance with the specifications in the documentation. • There is no damage to the robot that could be attributed to external forces. Example: Dents or abrasion that could be caused by an impact or collision. WARNING Danger to life and limb resulting from external forces The external application of force, such as an impact or a collision, can cause non-visible damage. For example, it can lead to a gradual loss of drive power from the motor, resulting in unintended movements of the manipulator. Death, severe injuries or damage to property may result from nonvisible damage. ‒ Check the robot for damage that could have been caused by external forces, e.g. dents or abrasion of paintwork. Check the motor and counterbalancing system particularly carefully. (Motor inspection not relevant for robots with internal motors.) ‒ In the case of damage, the affected components must be exchanged. • There are no foreign bodies or defective or loose parts on the industrial robot. • All required safety equipment is correctly installed and operational. • The power supply ratings of the industrial robot correspond to the local supply voltage and mains type. 34/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 • The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. • The connecting cables are correctly connected and the connectors are locked. 3.5.4 Manual mode General Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes: • • • • Jog mode Teaching Programming Program verification The following must be taken into consideration in manual mode: • New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). • The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence. • Workpieces, tooling and other objects must not jam as a result of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off. • All setup work must be carried out, where possible, from outside the safeguarded area. Setup work in T1 If it can be avoided, there must be no persons inside the safeguarded area. If it is necessary to carry out setup work from inside the safeguarded area, the following must be taken into consideration in the operating mode Manual Reduced Velocity (T1): • If it can be avoided, there must be no more than one person inside the safeguarded area. • If it is necessary for there to be several persons inside the safeguarded area, the following must be observed: ‒ Each person must have an enabling device. ‒ All persons must have an unimpeded view of the industrial robot. ‒ Eye-contact between all persons must be possible at all times. • The operator must be so positioned that he can see into the danger zone and get out of harm’s way. • Unexpected motions of the manipulator cannot be ruled out, e.g. in the event of a fault. For this reason, an appropriate clearance must be maintained between persons and the manipulator, including the tool. Guide value: 50 cm. The minimum clearance may vary depending on local circumstances, the motion program and other factors. The minimum clearance that is to apply for the specific application must be decided by the user on the basis of a risk assessment. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 35/651 Safety KR QUANTEC-2 Safety KR QUANTEC-2 Setup work in T2 If it is necessary to carry out setup work from inside the safeguarded area, the following must be taken into consideration in the operating mode Manual High Velocity (T2): • This mode may only be used if the application requires a test at a velocity higher than that possible in T1 mode. • Teaching and programming are not permissible in this operating mode. • Before commencing the test, the operator must ensure that the enabling devices are operational. • The operator must be positioned outside the danger zone. • There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this. 3.5.5 Automatic mode Automatic mode is only permissible in compliance with the following safety measures: • All safety equipment and safeguards are present and operational. • There are no persons in the system or the requirements for collaborative operation in accordance with EN ISO 10218 have been met. • The defined working procedures are adhered to. If the manipulator or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered. 3.5.6 Maintenance and repair After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on the industrial robot: • Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel. • Switch off the industrial robot and secure it (e.g. with a padlock) to prevent it from being switched on again. If it is necessary to carry out work with the robot controller switched on, the user must define additional safety measures to ensure the safe protection of personnel. • If it is necessary to carry out work with the robot controller switched on, this may only be done in operating mode T1. • Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work. • The EMERGENCY STOP devices must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. 36/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 DANGER Danger to life and limb due to live parts The robot system must be disconnected from the mains power supply prior to work on live parts. It is not sufficient to trigger an EMERGENCY STOP or safety stop, because parts remain live. Death or severe injuries may result. • Before commencing work on live parts, turn off the main switch and secure it against being switched on again. If the controller variant in question does not have a main switch (e.g. KR C5 micro), turn off the device switch then disconnect the power cable and secure it so it cannot be reconnected. • Then check to ensure that the system is deenergized. • Inform the individuals involved that the robot controller is switched off. (e.g. by affixing a warning sign) Faulty components must be replaced using new components with the same article numbers or equivalent components approved by the manufacturer for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions. Robot controller Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller. The ESD regulations must be adhered to when working on components in the robot controller. Voltages in excess of 50 V (up to 780 V) can be present in various components for several minutes after the robot controller has been switched off! To prevent life-threatening injuries, no work may be carried out on the industrial robot in this time. On robot controllers with transformers, the transformers must be disconnected before working on components in the robot controller. Water and dust must be prevented from entering the robot controller. Counterbalancing system Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbalancing system. • Counterbalancing system classified below category I: Is subject to the Pressure Equipment Directive but exempt from application of the Pressure Equipment Directive according to Art. 4, para. 3 and therefore not CE marked. • Counterbalancing system classified as category I or higher: Is subject to the Pressure Equipment Directive and CE marked as a component (see rating plate of the counterbalancing system). The pressure equipment is placed on the market in conjunction with partly completed machinery. Conformity is expressed on the declaration of incorporation according to the Machinery Directive. The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment. • In Germany, the counterbalancing system is work equipment according to the German Ordinance on Industrial Safety and Health (BetrSichV). Inspection intervals in Germany in accordance with the Ordinance on MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 37/651 Safety KR QUANTEC-2 KR QUANTEC-2 Safety Industrial Safety and Health, Sections 14 and 15. Inspection by the user before commissioning at the installation site. • Inspection intervals in all other countries must be researched and observed. As a rule, however, at least the maintenance intervals specified by KUKA must be observed. These must not be exceeded. The following safety measures must be carried out when working on the counterbalancing system: • The assemblies supported by the counterbalancing systems must be secured. • Work on the counterbalancing systems must only be carried out by qualified personnel. Hazardous substances The following safety measures must be carried out when handling hazardous substances: • Avoid prolonged and repeated intensive contact with the skin. • Avoid breathing in oil spray or vapors. • Clean skin and apply skin cream. Use current safety data sheets Knowledge of the safety data sheets of the substances and mixtures used is a prerequisite for the safe use of KUKA products. Death, injuries or damage to property may otherwise result. • Request up-to-date safety data sheets from the manufacturers of hazardous substances regularly. 3.5.7 Decommissioning, storage and disposal The industrial robot must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards. 38/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4 Technical data 4.1 Technical data, overview Technical data KR QUANTEC-2 The technical data for the individual robot types can be found in the following sections: Robot Technical data KR 120 R2700-2 • Technical data (>>> 4.2 "Technical data, KR 120 R2700-2" Page 43) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.2 "Stopping distances and times, KR 120 R2700-2 and KR 120 R2700-2 F" Page 354) KR 120 R2700-2 F • Technical data (>>> 4.3 "Technical data, KR 120 R2700-2 F" Page 56) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.2 "Stopping distances and times, KR 120 R2700-2 and KR 120 R2700-2 F" Page 354) KR 120 R3100-2 • Technical data (>>> 4.4 "Technical data, KR 120 R3100-2" Page 69) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.3 "Stopping distances and times, KR 120 R3100-2 and KR 120 R3100-2 F" Page 359) KR 120 R3100-2 F • Technical data (>>> 4.5 "Technical data, KR 120 R3100-2 F" Page 81) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.3 "Stopping distances and times, KR 120 R3100-2 and KR 120 R3100-2 F" Page 359) KR 150 R2700-2 • Technical data (>>> 4.6 "Technical data, KR 150 R2700-2" Page 93) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.4 "Stopping distances and times, KR 150 R2700-2 and KR 150 R2700-2 F" Page 365) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 39/651 Technical data KR QUANTEC-2 Robot Technical data KR 150 R2700-2 F • Technical data (>>> 4.7 "Technical data, KR 150 R2700-2 F" Page 106) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.4 "Stopping distances and times, KR 150 R2700-2 and KR 150 R2700-2 F" Page 365) KR 150 R3100-2 • Technical data (>>> 4.8 "Technical data, KR 150 R3100-2" Page 119) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.5 "Stopping distances and times, KR 150 R3100-2 and KR 150 R3100-2 F" Page 371) KR 150 R3100-2 F • Technical data (>>> 4.9 "Technical data, KR 150 R3100-2 F" Page 131) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.5 "Stopping distances and times, KR 150 R3100-2 and KR 150 R3100-2 F" Page 371) KR 180 R2900-2 • Technical data (>>> 4.10 "Technical data, KR 180 R2900-2" Page 143) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.6 "Stopping distances and times, KR 180 R2900-2 and KR 180 R2900-2 F" Page 377) KR 180 R2900-2 F • Technical data (>>> 4.11 "Technical data, KR 180 R2900-2 F" Page 156) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.6 "Stopping distances and times, KR 180 R2900-2 and KR 180 R2900-2 F" Page 377) KR 210 R2700-2 • Technical data (>>> 4.12 "Technical data, KR 210 R2700-2" Page 169) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.7 "Stopping distances and times, KR 210 R2700-2 and KR 210 R2700-2 F" Page 383) 40/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Robot Technical data KR 210 R2700-2 F • Technical data (>>> 4.13 "Technical data, KR 210 R2700-2 F" Page 182) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.7 "Stopping distances and times, KR 210 R2700-2 and KR 210 R2700-2 F" Page 383) KR 210 R3100-2 • Technical data (>>> 4.14 "Technical data, KR 210 R3100-2" Page 195) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.8 "Stopping distances and times, KR 210 R3100-2, KR 210 R3100-2 F and KR 210 R3100-2 C" Page 389) KR 210 R3100-2 F • Technical data (>>> 4.15 "Technical data, KR 210 R3100-2 F" Page 207) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.8 "Stopping distances and times, KR 210 R3100-2, KR 210 R3100-2 F and KR 210 R3100-2 C" Page 389) KR 210 R3100-2 C • Technical data (>>> 4.16 "Technical data, KR 210 R3100-2 C" Page 219) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.8 "Stopping distances and times, KR 210 R3100-2, KR 210 R3100-2 F and KR 210 R3100-2 C" Page 389) KR 240 R2900-2 • Technical data (>>> 4.17 "Technical data, KR 240 R2900-2" Page 231) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.9 "Stopping distances and times, KR 240 R2900-2, KR 240 R2900-2 F and KR 240 R2900-2 C" Page 395) KR 240 R2900-2 F • Technical data (>>> 4.18 "Technical data, KR 240 R2900-2 F" Page 244) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.9 "Stopping distances and times, KR 240 R2900-2, KR 240 R2900-2 F and KR 240 R2900-2 C" Page 395) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 41/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Robot Technical data KR 240 R2900-2 C • Technical data (>>> 4.19 "Technical data, KR 240 R2900-2 C" Page 257) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.9 "Stopping distances and times, KR 240 R2900-2, KR 240 R2900-2 F and KR 240 R2900-2 C" Page 395) KR 250 R2700-2 • Technical data (>>> 4.20 "Technical data, KR 250 R2700-2" Page 270) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.10 "Stopping distances and times, KR 250 R2700-2, KR 250 R2700-2 F and KR 250 R2700-2 C" Page 401) KR 250 R2700-2 F • Technical data (>>> 4.21 "Technical data, KR 250 R2700-2 F" Page 283) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.10 "Stopping distances and times, KR 250 R2700-2, KR 250 R2700-2 F and KR 250 R2700-2 C" Page 401) KR 250 R2700-2 C • Technical data (>>> 4.22 "Technical data, KR 250 R2700-2 C" Page 296) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.10 "Stopping distances and times, KR 250 R2700-2, KR 250 R2700-2 F and KR 250 R2700-2 C" Page 401) KR 300 R2700-2 • Technical data (>>> 4.23 "Technical data, KR 300 R2700-2" Page 309) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.11 "Stopping distances and times, KR 300 R2700-2, KR 300 R2700-2 F and KR 300 R2700-2 C" Page 407) KR 300 R2700-2 F • Technical data (>>> 4.24 "Technical data, KR 300 R2700-2 F" Page 322) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.11 "Stopping distances and times, KR 300 R2700-2, KR 300 R2700-2 F and KR 300 R2700-2 C" Page 407) 42/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Robot Technical data KR 300 R2700-2 C • Technical data (>>> 4.25 "Technical data, KR 300 R2700-2 C" Page 335) • Plates and labels (>>> 4.26 "Plates and labels" Page 348) • Stopping distances and stopping times (>>> 4.28.11 "Stopping distances and times, KR 300 R2700-2, KR 300 R2700-2 F and KR 300 R2700-2 C" Page 407) 4.2 Technical data, KR 120 R2700-2 4.2.1 Basic data, KR 120 R2700-2 Basic data KR 120 R2700-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1069 kg Rated payload 120 kg Maximum payload 167 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 Transformation name KR C4: KR120R2700_2 C4 FLR; KR C5: KR120R2700_2 C4 FLR MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 43/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Cable designation Motor cable Connector designation robot controller robot 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable 44/651 | www.kuka.com XF21 - XF31 Han® 3A Q12 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connector designation robot controller robot Cable designation Ground conductor / equipotential bonding 16 mm2 Interface with robot M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.2.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 120 R2700-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 120 °/s A2 115 °/s A3 120 °/s A4 190 °/s A5 180 °/s A6 260 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 45/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-1: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 46/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-2: KR 120 R2700-2, working envelope, side view Fig. 4-3: KR 120 R2700-2, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 47/651 Technical data KR QUANTEC-2 4.2.3 Payloads, KR 120 R2700-2 Payloads Rated payload 120 kg Maximum payload 167 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-4: Load center of gravity and mass moment of inertia Parameter 48/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 49/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-5: Payload diagram, KR 120 R2700-2 The KR 120 R2700-2 is designed for a rated payload of 120 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 167 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH210 Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 50/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-6: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-7: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4005 N www.kuka.com | 51/651 Technical data KR QUANTEC-2 F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 52/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-8: Fastening of supplementary load on arm/in-line wrist, KR 120 R2700-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 53/651 Technical data KR QUANTEC-2 Fig. 4-9: Fastening of supplementary load on rotating column/link arm, KR 120 R2700-2 4.2.4 Foundation loads, KR 120 R2700-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 54/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 55/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-10: Foundation loads 4.3 Technical data, KR 120 R2700-2 F 4.3.1 Basic data, KR 120 R2700-2 F Basic data KR 120 R2700-2 F 56/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1069 kg Rated payload 120 kg Maximum payload 167 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 120 R2700-2 F Transformation name KR C4: KR120R2700_2 C4 FLR; KR C5: KR120R2700_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 57/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.3.2 Axis data, KR 120 R2700-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 58/651 | www.kuka.com 120 °/s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 A2 115 °/s A3 120 °/s A4 190 °/s A5 180 °/s A6 260 °/s Technical data KR QUANTEC-2 Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-11: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 59/651 Technical data KR QUANTEC-2 Fig. 4-12: KR 120 R2700-2 F, working envelope, side view Fig. 4-13: KR 120 R2700-2 F, working envelope, top view 60/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.3.3 Technical data KR QUANTEC-2 Payloads, KR 120 R2700-2 F Payloads Rated payload 120 kg Maximum payload 167 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-14: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 61/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 62/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-15: Payload diagram, KR 120 R2700-2 F The KR 120 R2700-2 F is designed for a rated payload of 120 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 167 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH210 F Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 63/651 Technical data KR QUANTEC-2 Fig. 4-16: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-17: Flange loads Flange loads during operation F(a) 64/651 | www.kuka.com 4005 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 65/651 Technical data KR QUANTEC-2 Fig. 4-18: Fastening of supplementary load on arm/in-line wrist, KR 120 R2700-2 F 66/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-19: Fastening of supplementary load on rotating column/link arm, KR 120 R2700-2 F 4.3.4 Foundation loads, KR 120 R2700-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 67/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 68/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-20: Foundation loads 4.4 Technical data, KR 120 R3100-2 4.4.1 Basic data, KR 120 R3100-2 Basic data KR 120 R3100-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 86.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 120 kg Maximum payload 210 kg Maximum reach 3100 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 69/651 Technical data KR QUANTEC-2 KR 120 R3100-2 Transformation name KR C4: KR120R3100_2 C4 FLR; KR C5: KR120R3100_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 70/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.4.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 120 R3100-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 120 °/s A2 115 °/s A3 120 °/s A4 190 °/s A5 180 °/s A6 260 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 71/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-21: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 72/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-22: KR 120 R3100-2, working envelope, side view Fig. 4-23: KR 120 R3100-2, working envelope, top view 4.4.3 Payloads, KR 120 R3100-2 Payloads Rated payload 120 kg Maximum payload 210 kg Rated supplementary load, base frame 0 kg MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 73/651 Technical data KR QUANTEC-2 Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-24: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system A, B, C Degrees Orientation of the principal inertia axes • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: 74/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! Fig. 4-25: Payload diagram, KR 120 R3100-2 The KR 120 R3100-2 is designed for a rated payload of 120 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 210 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 75/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Mounting flange Robot wrist type ZH210 Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. Fig. 4-26: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. 76/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-27: Flange loads Flange loads during operation F(a) 4005 N F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 77/651 Technical data KR QUANTEC-2 Fig. 4-28: Fastening of supplementary load on arm/in-line wrist, KR 120 R3100-2 78/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-29: Fastening of supplementary load on rotating column/link arm, KR 120 R3100-2 4.4.4 Foundation loads, KR 120 R3100-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 79/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 80/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-30: Foundation loads 4.5 Technical data, KR 120 R3100-2 F 4.5.1 Basic data, KR 120 R3100-2 F Basic data KR 120 R3100-2 F Number of axes 6 Number of controlled axes 6 Volume of working envelope 86.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 120 kg Maximum payload 210 kg Maximum reach 3100 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 81/651 Technical data KR QUANTEC-2 KR 120 R3100-2 F Transformation name KR C4: KR120R3100_2 C4 FLR; KR C5: KR120R3100_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. 82/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.5.2 Axis data, KR 120 R3100-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 120 °/s www.kuka.com | 83/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 A2 115 °/s A3 120 °/s A4 190 °/s A5 180 °/s A6 260 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-31: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 84/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-32: KR 120 R3100-2 F, working envelope, side view Fig. 4-33: KR 120 R3100-2 F, working envelope, top view 4.5.3 Payloads, KR 120 R3100-2 F Payloads Rated payload 120 kg Maximum payload 210 kg Rated supplementary load, base frame 0 kg MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 85/651 Technical data KR QUANTEC-2 Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-34: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system A, B, C Degrees Orientation of the principal inertia axes • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: 86/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! Fig. 4-35: Payload diagram, KR 120 R3100-2 F The KR 120 R3100-2 F is designed for a rated payload of 120 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 210 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 87/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Mounting flange Robot wrist type ZH210 F Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. Fig. 4-36: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. 88/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-37: Flange loads Flange loads during operation F(a) 4005 N F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 89/651 Technical data KR QUANTEC-2 Fig. 4-38: Fastening of supplementary load on arm/in-line wrist, KR 120 R3100-2 F 90/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-39: Fastening of supplementary load on rotating column/link arm, KR 120 R3100-2 F 4.5.4 Foundation loads, KR 120 R3100-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 91/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 92/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-40: Foundation loads 4.6 Technical data, KR 150 R2700-2 4.6.1 Basic data, KR 150 R2700-2 Basic data KR 150 R2700-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1072 kg Rated payload 150 kg Maximum payload 218 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 93/651 Technical data KR QUANTEC-2 KR 150 R2700-2 Transformation name KR C4: KR150R2700_2 C4 FLR; KR C5: KR150R2700_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 94/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.6.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 150 R2700-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 120 °/s A2 115 °/s A3 120 °/s A4 190 °/s A5 180 °/s A6 260 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 95/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-41: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 96/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-42: KR 150 R2700-2, working envelope, side view Fig. 4-43: KR 150 R2700-2, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 97/651 Technical data KR QUANTEC-2 4.6.3 Payloads, KR 150 R2700-2 Payloads Rated payload 150 kg Maximum payload 218 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-44: Load center of gravity and mass moment of inertia Parameter 98/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 99/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-45: Payload diagram, KR 150 R2700-2 The KR 150 R2700-2 is designed for a rated payload of 150 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 218 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH210 Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 100/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-46: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-47: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4005 N www.kuka.com | 101/651 Technical data KR QUANTEC-2 F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 102/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-48: Fastening of supplementary load on arm/in-line wrist, KR 150 R2700-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 103/651 Technical data KR QUANTEC-2 Fig. 4-49: Fastening of supplementary load on rotating column/link arm, KR 150 R2700-2 4.6.4 Foundation loads, KR 150 R2700-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 104/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 105/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-50: Foundation loads 4.7 Technical data, KR 150 R2700-2 F 4.7.1 Basic data, KR 150 R2700-2 F Basic data KR 150 R2700-2 F 106/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1072 kg Rated payload 150 kg Maximum payload 218 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 150 R2700-2 F Transformation name KR C4: KR150R2700_2 C4 FLR; KR C5: KR150R2700_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 107/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.7.2 Axis data, KR 150 R2700-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 108/651 | www.kuka.com 120 °/s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 A2 115 °/s A3 120 °/s A4 190 °/s A5 180 °/s A6 260 °/s Technical data KR QUANTEC-2 Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-51: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 109/651 Technical data KR QUANTEC-2 Fig. 4-52: KR 150 R2700-2 F, working envelope, side view Fig. 4-53: KR 150 R2700-2 F, working envelope, top view 110/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.7.3 Technical data KR QUANTEC-2 Payloads, KR 150 R2700-2 F Payloads Rated payload 150 kg Maximum payload 218 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-54: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 111/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 112/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-55: Payload diagram, KR 150 R2700-2 F The KR 150 R2700-2 F is designed for a rated payload of 150 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 218 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH210 F Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 113/651 Technical data KR QUANTEC-2 Fig. 4-56: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-57: Flange loads Flange loads during operation F(a) 114/651 | www.kuka.com 4005 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 115/651 Technical data KR QUANTEC-2 Fig. 4-58: Fastening of supplementary load on arm/in-line wrist, KR 150 R2700-2 F 116/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-59: Fastening of supplementary load on rotating column/link arm, KR 150 R2700-2 F 4.7.4 Foundation loads, KR 150 R2700-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 117/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 118/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-60: Foundation loads 4.8 Technical data, KR 150 R3100-2 4.8.1 Basic data, KR 150 R3100-2 Basic data KR 150 R3100-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 86.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 150 kg Maximum payload 220 kg Maximum reach 3100 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 119/651 Technical data KR QUANTEC-2 KR 150 R3100-2 Transformation name KR C4: KR150R3100_2 C4 FLR; KR C5: KR150R3100_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 120/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.8.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 150 R3100-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 107 °/s A3 114 °/s A4 190 °/s A5 180 °/s A6 260 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 121/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-61: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 122/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-62: KR 150 R3100-2, working envelope, side view Fig. 4-63: KR 150 R3100-2, working envelope, top view 4.8.3 Payloads, KR 150 R3100-2 Payloads Rated payload 150 kg Maximum payload 220 kg Rated supplementary load, base frame 0 kg MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 123/651 Technical data KR QUANTEC-2 Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-64: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system A, B, C Degrees Orientation of the principal inertia axes • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: 124/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! Fig. 4-65: Payload diagram, KR 150 R3100-2 The KR 150 R3100-2 is designed for a rated payload of 150 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 220 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 125/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Mounting flange Robot wrist type ZH210 Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. Fig. 4-66: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. 126/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-67: Flange loads Flange loads during operation F(a) 4005 N F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 127/651 Technical data KR QUANTEC-2 Fig. 4-68: Fastening of supplementary load on arm/in-line wrist, KR 150 R3100-2 128/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-69: Fastening of supplementary load on rotating column/link arm, KR 150 R3100-2 4.8.4 Foundation loads, KR 150 R3100-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 129/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 130/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-70: Foundation loads 4.9 Technical data, KR 150 R3100-2 F 4.9.1 Basic data, KR 150 R3100-2 F Basic data KR 150 R3100-2 F Number of axes 6 Number of controlled axes 6 Volume of working envelope 86.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 150 kg Maximum payload 220 kg Maximum reach 3100 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 131/651 Technical data KR QUANTEC-2 KR 150 R3100-2 F Transformation name KR C4: KR150R3100_2 C4 FLR; KR C5: KR150R3100_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. 132/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.9.2 Axis data, KR 150 R3100-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 105 °/s www.kuka.com | 133/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 A2 107 °/s A3 114 °/s A4 190 °/s A5 180 °/s A6 260 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-71: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 134/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-72: KR 150 R3100-2 F, working envelope, side view Fig. 4-73: KR 150 R3100-2 F, working envelope, top view 4.9.3 Payloads, KR 150 R3100-2 F Payloads Rated payload 150 kg Maximum payload 220 kg Rated supplementary load, base frame 0 kg MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 135/651 Technical data KR QUANTEC-2 Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-74: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system A, B, C Degrees Orientation of the principal inertia axes • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: 136/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! Fig. 4-75: Payload diagram, KR 150 R3100-2 F The KR 150 R3100-2 F is designed for a rated payload of 150 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 220 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 137/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Mounting flange Robot wrist type ZH210 F Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. Fig. 4-76: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. 138/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-77: Flange loads Flange loads during operation F(a) 4005 N F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 139/651 Technical data KR QUANTEC-2 Fig. 4-78: Fastening of supplementary load on arm/in-line wrist, KR 150 R3100-2 F 140/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-79: Fastening of supplementary load on rotating column/link arm, KR 150 R3100-2 F 4.9.4 Foundation loads, KR 150 R3100-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 141/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 142/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-80: Foundation loads 4.10 Technical data, KR 180 R2900-2 4.10.1 Basic data, KR 180 R2900-2 Basic data KR 180 R2900-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 68 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 180 kg Maximum payload 253 kg Maximum reach 2900 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 143/651 Technical data KR QUANTEC-2 KR 180 R2900-2 Transformation name KR C4: KR180R2900_2 C4 FLR; KR C5: KR180R2900_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 144/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.10.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 180 R2900-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 107 °/s A3 114 °/s A4 179 °/s A5 172 °/s A6 219 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 145/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-81: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 146/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-82: KR 180 R2900-2, working envelope, side view Fig. 4-83: KR 180 R2900-2, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 147/651 Technical data KR QUANTEC-2 4.10.3 Payloads, KR 180 R2900-2 Payloads Rated payload 180 kg Maximum payload 253 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-84: Load center of gravity and mass moment of inertia Parameter 148/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 149/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-85: Payload diagram, KR 180 R2900-2 The KR 180 R2900-2 is designed for a rated payload of 180 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 253 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 150/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-86: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-87: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 5127 N www.kuka.com | 151/651 Technical data KR QUANTEC-2 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 152/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-88: Fastening of supplementary load, arm/in-line wrist, KR 180 R2900-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 153/651 Technical data KR QUANTEC-2 Fig. 4-89: Fastening of supplementary load on rotating column/link arm, KR 180 R2900-2 4.10.4 Foundation loads, KR 180 R2900-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 154/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 155/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-90: Foundation loads 4.11 Technical data, KR 180 R2900-2 F 4.11.1 Basic data, KR 180 R2900-2 F Basic data KR 180 R2900-2 F 156/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 68 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 180 kg Maximum payload 253 kg Maximum reach 2900 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 180 R2900-2 F Transformation name KR C4: KR180R2900_2 C4 FLR; KR C5: KR180R2900_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 157/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.11.2 Axis data, KR 180 R2900-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 158/651 | www.kuka.com 105 °/s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 A2 107 °/s A3 114 °/s A4 179 °/s A5 172 °/s A6 219 °/s Technical data KR QUANTEC-2 Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-91: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 159/651 Technical data KR QUANTEC-2 Fig. 4-92: KR 180 R2900-2 F, working envelope, side view Fig. 4-93: KR 180 R2900-2 F, working envelope, top view 160/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.11.3 Technical data KR QUANTEC-2 Payloads, KR 180 R2900-2 F Payloads Rated payload 180 kg Maximum payload 253 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-94: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 161/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 162/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-95: Payload diagram, KR 180 R2900-2 F The KR 180 R2900-2 F is designed for a rated payload of 180 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 253 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 F Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 163/651 Technical data KR QUANTEC-2 Fig. 4-96: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-97: Flange loads Flange loads during operation F(a) 164/651 | www.kuka.com 5127 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 165/651 Technical data KR QUANTEC-2 Fig. 4-98: Fastening of supplementary load, arm/in-line wrist, KR 180 R2900-2 F 166/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-99: Fastening of supplementary load on rotating column/link arm, KR 180 R2900-2 F 4.11.4 Foundation loads, KR 180 R2900-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 167/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 168/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-100: Foundation loads 4.12 Technical data, KR 210 R2700-2 4.12.1 Basic data, KR 210 R2700-2 Basic data KR 210 R2700-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1077 kg Rated payload 210 kg Maximum payload 275 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 169/651 Technical data KR QUANTEC-2 KR 210 R2700-2 Transformation name KR C4: KR210R2700_2 C4 FLR; KR C5: KR210R2700_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) Class 6 at 40% override; Class 6 at 80% override Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 170/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.12.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 210 R2700-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 120 °/s A2 115 °/s A3 112 °/s A4 179 °/s A5 172 °/s A6 220 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 171/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-101: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 172/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-102: KR 210 R2700-2, working envelope, side view Fig. 4-103: KR 210 R2700-2, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 173/651 Technical data KR QUANTEC-2 4.12.3 Payloads, KR 210 R2700-2 Payloads Rated payload 210 kg Maximum payload 275 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-104: Load center of gravity and mass moment of inertia Parameter 174/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 175/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-105: Payload diagram, KR 210 R2700-2 The KR 210 R2700-2 is designed for a rated payload of 210 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 275 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH210 Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 176/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-106: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-107: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4005 N www.kuka.com | 177/651 Technical data KR QUANTEC-2 F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 178/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-108: Fastening of supplementary load on arm/in-line wrist, KR 210 R2700-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 179/651 Technical data KR QUANTEC-2 Fig. 4-109: Fastening of supplementary load on rotating column/link arm, KR 210 R2700-2 4.12.4 Foundation loads, KR 210 R2700-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 180/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 181/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-110: Foundation loads 4.13 Technical data, KR 210 R2700-2 F 4.13.1 Basic data, KR 210 R2700-2 F Basic data KR 210 R2700-2 F 182/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1077 kg Rated payload 210 kg Maximum payload 275 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 210 R2700-2 F Transformation name KR C4: KR210R2700_2 C4 FLR; KR C5: KR210R2700_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 183/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.13.2 Axis data, KR 210 R2700-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±125 ° A6 ±350 ° Speed with rated payload A1 184/651 | www.kuka.com 120 °/s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 A2 115 °/s A3 112 °/s A4 179 °/s A5 172 °/s A6 220 °/s Technical data KR QUANTEC-2 Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-111: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 185/651 Technical data KR QUANTEC-2 Fig. 4-112: KR 210 R2700-2 F, working envelope, side view Fig. 4-113: KR 210 R2700-2 F, working envelope, top view 186/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.13.3 Technical data KR QUANTEC-2 Payloads, KR 210 R2700-2 F Payloads Rated payload 210 kg Maximum payload 275 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-114: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 187/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 188/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-115: Payload diagram, KR 210 R2700-2 F The KR 210 R2700-2 F is designed for a rated payload of 210 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 275 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH210 F Mounting flange standard Deviation, see figure Diameter (hole circle) 125 mm Thread diameter M10 Depth of engagement min. 11.5 mm, max. 16 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 189/651 Technical data KR QUANTEC-2 Fig. 4-116: Mounting flange D=125 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-117: Flange loads Flange loads during operation F(a) 190/651 | www.kuka.com 4005 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 3631 N M(k) 2343 Nm M(g) 1007 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 6167 N F(r) 8625 N M(k) 5862 Nm M(g) 4463 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 191/651 Technical data KR QUANTEC-2 Fig. 4-118: Fastening of supplementary load on arm/in-line wrist, KR 210 R2700-2 F 192/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-119: Fastening of supplementary load on rotating column/link arm, KR 210 R2700-2 F 4.13.4 Foundation loads, KR 210 R2700-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 193/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 194/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-120: Foundation loads 4.14 Technical data, KR 210 R3100-2 4.14.1 Basic data, KR 210 R3100-2 Basic data KR 210 R3100-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 86.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1134 kg Rated payload 210 kg Maximum payload 281 kg Maximum reach 3100 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 195/651 Technical data KR QUANTEC-2 KR 210 R3100-2 Transformation name KR C4: KR210R3100_2 C4 FLR; KR C5: KR210R3100_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 196/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.14.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 210 R3100-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 94 °/s A3 100 °/s A4 136 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 197/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-121: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 198/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-122: KR 210 R3100-2, working envelope, side view Fig. 4-123: KR 210 R3100-2, working envelope, top view 4.14.3 Payloads, KR 210 R3100-2 Payloads Rated payload 210 kg Maximum payload 281 kg Rated supplementary load, base frame 0 kg MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 199/651 Technical data KR QUANTEC-2 Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-124: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system A, B, C Degrees Orientation of the principal inertia axes • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: 200/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! Fig. 4-125: Payload diagram, KR 210 R3100-2 The KR 210 R3100-2 is designed for a rated payload of 210 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 281 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 201/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. Fig. 4-126: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. 202/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-127: Flange loads Flange loads during operation F(a) 5127 N F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 203/651 Technical data KR QUANTEC-2 Fig. 4-128: Fastening of supplementary load on arm/in-line wrist, KR 210 R3100-2 204/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-129: Fastening of supplementary load on rotating column/link arm, KR 210 R3100-2 4.14.4 Foundation loads, KR 210 R3100-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 205/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 206/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-130: Foundation loads 4.15 Technical data, KR 210 R3100-2 F 4.15.1 Basic data, KR 210 R3100-2 F Basic data KR 210 R3100-2 F Number of axes 6 Number of controlled axes 6 Volume of working envelope 86.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1134 kg Rated payload 210 kg Maximum payload 281 kg Maximum reach 3100 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 207/651 Technical data KR QUANTEC-2 KR 210 R3100-2 F Transformation name KR C4: KR210R3100_2 C4 FLR; KR C5: KR210R3100_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. 208/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.15.2 Axis data, KR 210 R3100-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 105 °/s www.kuka.com | 209/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 A2 94 °/s A3 100 °/s A4 136 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-131: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 210/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-132: KR 210 R3100-2 F, working envelope, side view Fig. 4-133: KR 210 R3100-2 F, working envelope, top view 4.15.3 Payloads, KR 210 R3100-2 F Payloads Rated payload 210 kg Maximum payload 281 kg Rated supplementary load, base frame 0 kg MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 211/651 Technical data KR QUANTEC-2 Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-134: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system A, B, C Degrees Orientation of the principal inertia axes • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: 212/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! Fig. 4-135: Payload diagram, KR 210 R3100-2 F The KR 210 R3100-2 F is designed for a rated payload of 210 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 281 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 213/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Mounting flange Robot wrist type ZH300 F Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. Fig. 4-136: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. 214/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-137: Flange loads Flange loads during operation F(a) 5127 N F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 215/651 Technical data KR QUANTEC-2 Fig. 4-138: Fastening of supplementary load on arm/in-line wrist, KR 210 R3100-2 F 216/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-139: Fastening of supplementary load on rotating column/link arm, KR 210 R3100-2 F 4.15.4 Foundation loads, KR 210 R3100-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 217/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 218/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-140: Foundation loads 4.16 Technical data, KR 210 R3100-2 C 4.16.1 Basic data, KR 210 R3100-2 C Basic data KR 210 R3100-2 C Number of axes 6 Number of controlled axes 6 Volume of working envelope 79.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1139 kg Rated payload 210 kg Maximum payload 255 kg Maximum reach 3065 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Ceiling Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 0 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 219/651 Technical data KR QUANTEC-2 KR 210 R3100-2 C Transformation name KR C4: KR210R3100_2 C4 CLG; KR C5: KR210R3100_2 C4 CLG The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 220/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.16.2 Axis data, KR 210 R3100-2 C Axis data Motion range A1 ±185 ° A2 -140 ° / -14 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 94 °/s A3 100 °/s A4 136 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 221/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-141: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 222/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-142: KR 210 R3100-2 C, working envelope, side view Fig. 4-143: KR 210 R3100-2 C, working envelope, top view 4.16.3 Payloads, KR 210 R3100-2 C Payloads Rated payload 210 kg Maximum payload 255 kg MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 223/651 Technical data KR QUANTEC-2 Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-144: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system A, B, C Degrees Orientation of the principal inertia axes • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. 224/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! Fig. 4-145: Payload diagram, KR 210 R3100-2 C The KR 210 R3100-2 C is designed for a rated payload of 210 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 255 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 225/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. Fig. 4-146: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. 226/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-147: Flange loads Flange loads during operation F(a) 4800 N F(r) 4500 N M(k) 3200 Nm M(g) 1700 Nm Flange loads in the case of EMERGENCY STOP F(a) 8700 N F(r) 12600 N M(k) 6700 Nm M(g) 5700 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 227/651 Technical data KR QUANTEC-2 Fig. 4-148: Fastening of supplementary load on arm/in-line wrist, KR 210 R3100-2 C 228/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-149: Fastening of supplementary load on rotating column/link arm, KR 210 R3100-2 C 4.16.4 Foundation loads, KR 210 R3100-2 C Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 229/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 17000 N F(v max) 24900 N Horizontal force F(h) F(h normal) 8600 N F(h max) 20600 N Tilting moment M(k) M(k normal) 19800 Nm M(k max) 43200 Nm Torque about axis 1 M(r) 230/651 | www.kuka.com M(r normal) 8000 Nm M(r max) 17300 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-150: Foundation loads 4.17 Technical data, KR 240 R2900-2 4.17.1 Basic data, KR 240 R2900-2 Basic data KR 240 R2900-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 68 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1120 kg Rated payload 240 kg Maximum payload 319 kg Maximum reach 2900 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 231/651 Technical data KR QUANTEC-2 KR 240 R2900-2 Transformation name KR C4: KR240R2900_2 C4 FLR; KR C5: KR240R2900_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 232/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.17.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 240 R2900-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 103 °/s A2 94 °/s A3 100 °/s A4 170 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 233/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-151: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 234/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-152: KR 240 R2900-2, working envelope, side view Fig. 4-153: KR 240 R2900-2, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 235/651 Technical data KR QUANTEC-2 4.17.3 Payloads, KR 240 R2900-2 Payloads Rated payload 240 kg Maximum payload 319 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-154: Load center of gravity and mass moment of inertia Parameter 236/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 237/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-155: KR 240 R2900-2, payload diagram The KR 240 R2900-2 is designed for a rated payload of 240 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 319 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 238/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-156: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-157: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 5127 N www.kuka.com | 239/651 Technical data KR QUANTEC-2 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 240/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-158: Fastening of supplementary load, arm/in-line wrist, KR 240 R2900-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 241/651 Technical data KR QUANTEC-2 Fig. 4-159: Fastening of supplementary load on rotating column/link arm, KR 240 R2900-2 4.17.4 Foundation loads, KR 240 R2900-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 242/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 243/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-160: Foundation loads 4.18 Technical data, KR 240 R2900-2 F 4.18.1 Basic data, KR 240 R2900-2 F Basic data KR 240 R2900-2 F 244/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 68 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1120 kg Rated payload 240 kg Maximum payload 319 kg Maximum reach 2900 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 240 R2900-2 F Transformation name KR C4: KR240R2900_2 C4 FLR; KR C5: KR240R2900_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 245/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.18.2 Axis data, KR 240 R2900-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 246/651 | www.kuka.com 103 °/s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 A2 94 °/s A3 100 °/s A4 170 °/s A5 129 °/s A6 206 °/s Technical data KR QUANTEC-2 Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-161: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 247/651 Technical data KR QUANTEC-2 Fig. 4-162: KR 240 R2900-2 F, working envelope, side view Fig. 4-163: KR 240 R2900-2 F, working envelope, top view 248/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.18.3 Technical data KR QUANTEC-2 Payloads, KR 240 R2900-2 F Payloads Rated payload 240 kg Maximum payload 319 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-164: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 249/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 250/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-165: KR 240 R2900-2 F, payload diagram The KR 240 R2900-2 F is designed for a rated payload of 240 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 319 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 F Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 251/651 Technical data KR QUANTEC-2 Fig. 4-166: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-167: Flange loads Flange loads during operation F(a) 252/651 | www.kuka.com 5127 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 253/651 Technical data KR QUANTEC-2 Fig. 4-168: Fastening of supplementary load, arm/in-line wrist, KR 240 R2900-2 F 254/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-169: Fastening of supplementary load on rotating column/link arm, KR 240 R2900-2 F 4.18.4 Foundation loads, KR 240 R2900-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 255/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 256/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-170: Foundation loads 4.19 Technical data, KR 240 R2900-2 C 4.19.1 Basic data, KR 240 R2900-2 C Basic data KR 240 R2900-2 C Number of axes 6 Number of controlled axes 6 Volume of working envelope 62.1 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1125 kg Rated payload 240 kg Maximum payload 292 kg Maximum reach 2865 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Ceiling Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 0 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 257/651 Technical data KR QUANTEC-2 KR 240 R2900-2 C Transformation name KR C4: KR240R2900_2 C4 CLG; KR C5: KR240R2900_2 C4 CLG The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 258/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.19.2 Axis data, KR 240 R2900-2 C Axis data Motion range A1 ±185 ° A2 -140 ° / -14 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 103 °/s A2 94 °/s A3 100 °/s A4 170 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 259/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-171: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 260/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-172: KR 240 R2900-2 C, working envelope, side view Fig. 4-173: KR 240 R2900-2 C, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 261/651 Technical data KR QUANTEC-2 4.19.3 Payloads, KR 240 R2900-2 C Payloads Rated payload 240 kg Maximum payload 292 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-174: Load center of gravity and mass moment of inertia Parameter 262/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 263/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-175: KR 240 R2900-2 C, payload diagram The KR 240 R2900-2 C is designed for a rated payload of 240 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 292 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 264/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-176: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-177: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4800 N www.kuka.com | 265/651 Technical data KR QUANTEC-2 F(r) 4500 N M(k) 3200 Nm M(g) 1700 Nm Flange loads in the case of EMERGENCY STOP F(a) 8700 N F(r) 12600 N M(k) 6700 Nm M(g) 5700 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 266/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-178: Fastening of supplementary load, arm/in-line wrist, KR 240 R2900-2 C MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 267/651 Technical data KR QUANTEC-2 Fig. 4-179: Fastening of supplementary load on rotating column/link arm, KR 240 R2900-2 C 4.19.4 Foundation loads, KR 240 R2900-2 C Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 268/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 17000 N F(v max) 24900 N Horizontal force F(h) F(h normal) 8600 N F(h max) 20600 N Tilting moment M(k) M(k normal) 19800 Nm M(k max) 43200 Nm Torque about axis 1 M(r) M(r normal) 8000 Nm M(r max) 17300 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 269/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-180: Foundation loads 4.20 Technical data, KR 250 R2700-2 4.20.1 Basic data, KR 250 R2700-2 Basic data KR 250 R2700-2 270/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1101 kg Rated payload 250 kg Maximum payload 315 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 250 R2700-2 Transformation name KR C4: KR250R2700_2 C4 FLR; KR C5: KR250R2700_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 271/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.20.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 250 R2700-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 107 °/s A3 107 °/s A4 170 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. 272/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-181: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 273/651 Technical data KR QUANTEC-2 Fig. 4-182: KR 250 R2700-2, working envelope, side view Fig. 4-183: KR 250 R2700-2, working envelope, top view 274/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.20.3 Technical data KR QUANTEC-2 Payloads, KR 250 R2700-2 Payloads Rated payload 250 kg Maximum payload 315 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-184: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 275/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 276/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-185: Payload diagram, KR 250 R2700-2 The KR 250 R2700-2 is designed for a rated payload of 250 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 315 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 277/651 Technical data KR QUANTEC-2 Fig. 4-186: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-187: Flange loads Flange loads during operation F(a) 278/651 | www.kuka.com 5127 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 279/651 Technical data KR QUANTEC-2 Fig. 4-188: Fastening of supplementary load, arm/in-line wrist, KR 250 R2700-2 280/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-189: Fastening of supplementary load on rotating column/link arm, KR 250 R2700-2 4.20.4 Foundation loads, KR 250 R2700-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 281/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 282/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-190: Foundation loads 4.21 Technical data, KR 250 R2700-2 F 4.21.1 Basic data, KR 250 R2700-2 F Basic data KR 250 R2700-2 F Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1101 kg Rated payload 250 kg Maximum payload 315 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 283/651 Technical data KR QUANTEC-2 KR 250 R2700-2 F Transformation name KR C4: KR250R2700_2 C4 FLR; KR C5: KR250R2700_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. 284/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.21.2 Axis data, KR 250 R2700-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 105 °/s www.kuka.com | 285/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 A2 107 °/s A3 107 °/s A4 170 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-191: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 286/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-192: KR 250 R2700-2 F, working envelope, side view Fig. 4-193: KR 250 R2700-2 F, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 287/651 Technical data KR QUANTEC-2 4.21.3 Payloads, KR 250 R2700-2 F Payloads Rated payload 250 kg Maximum payload 315 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-194: Load center of gravity and mass moment of inertia Parameter 288/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 289/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-195: Payload diagram, KR 250 R2700-2 F The KR 250 R2700-2 F is designed for a rated payload of 250 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 315 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 F Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 290/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-196: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-197: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 5127 N www.kuka.com | 291/651 Technical data KR QUANTEC-2 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 292/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-198: Fastening of supplementary load, arm/in-line wrist, KR 250 R2700-2 F MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 293/651 Technical data KR QUANTEC-2 Fig. 4-199: Fastening of supplementary load on rotating column/link arm, KR 250 R2700-2 F 4.21.4 Foundation loads, KR 250 R2700-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 294/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 295/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-200: Foundation loads 4.22 Technical data, KR 250 R2700-2 C 4.22.1 Basic data, KR 250 R2700-2 C Basic data KR 250 R2700-2 C 296/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 51.8 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 250 kg Maximum payload 305 kg Maximum reach 2671 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Ceiling Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 0 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 250 R2700-2 C Transformation name KR C4: KR250R2700_2 C4 CLG; KR C5: KR250R2700_2 C4 CLG The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 297/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.22.2 Axis data, KR 250 R2700-2 C Axis data Motion range A1 ±185 ° A2 -140 ° / -14 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 107 °/s A3 107 °/s A4 170 °/s A5 129 °/s A6 206 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. 298/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-201: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 299/651 Technical data KR QUANTEC-2 Fig. 4-202: KR 250 R2700-2 C, working envelope, side view Fig. 4-203: KR 250 R2700-2 C, working envelope, top view 300/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.22.3 Technical data KR QUANTEC-2 Payloads, KR 250 R2700-2 C Payloads Rated payload 250 kg Maximum payload 305 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-204: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 301/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 302/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-205: Payload diagram, KR 250 R2700-2 C The KR 250 R2700-2 C is designed for a rated payload of 250 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 305 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 303/651 Technical data KR QUANTEC-2 Fig. 4-206: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-207: Flange loads Flange loads during operation F(a) 304/651 | www.kuka.com 4800 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 4500 N M(k) 3200 Nm M(g) 1700 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 8700 N F(r) 12600 N M(k) 6700 Nm M(g) 5700 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 305/651 Technical data KR QUANTEC-2 Fig. 4-208: Fastening of supplementary load, arm/in-line wrist, KR 250 R2700-2 C 306/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-209: Fastening of supplementary load on rotating column/link arm, KR 250 R2700-2 C 4.22.4 Foundation loads, KR 250 R2700-2 C Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 307/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 17000 N F(v max) 24900 N Horizontal force F(h) F(h normal) 8600 N F(h max) 20600 N Tilting moment M(k) M(k normal) 19800 Nm M(k max) 43200 Nm Torque about axis 1 M(r) 308/651 | www.kuka.com M(r normal) 8000 Nm M(r max) 17300 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-210: Foundation loads 4.23 Technical data, KR 300 R2700-2 4.23.1 Basic data, KR 300 R2700-2 Basic data KR 300 R2700-2 Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1101 kg Rated payload 300 kg Maximum payload 370 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 309/651 Technical data KR QUANTEC-2 KR 300 R2700-2 Transformation name KR C4: KR300R2700_2 C4 FLR; KR C5: KR300R2700_2 C4 FLR The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 310/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). Certificates ESD requirements 4.23.2 IEC61340-5-1; ANSI/ESD S20.20 Axis data, KR 300 R2700-2 Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 101 °/s A3 107 °/s A4 140 °/s A5 113 °/s A6 180 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 311/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-211: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 312/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-212: KR 300 R2700-2, working envelope, side view Fig. 4-213: KR 300 R2700-2, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 313/651 Technical data KR QUANTEC-2 4.23.3 Payloads, KR 300 R2700-2 Payloads Rated payload 300 kg Maximum payload 370 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-214: Load center of gravity and mass moment of inertia Parameter 314/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 315/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-215: Payload diagram, KR 300 R2700-2 The KR 300 R2700-2 is designed for a rated payload of 300 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 370 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 316/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-216: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-217: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 5127 N www.kuka.com | 317/651 Technical data KR QUANTEC-2 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 318/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-218: Fastening of supplementary load, arm/in-line wrist, KR 300 R2700-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 319/651 Technical data KR QUANTEC-2 Fig. 4-219: Fastening of supplementary load on rotating column/link arm, KR 300 R2700-2 4.23.4 Foundation loads, KR 300 R2700-2 Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 320/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 321/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-220: Foundation loads 4.24 Technical data, KR 300 R2700-2 F 4.24.1 Basic data, KR 300 R2700-2 F Basic data KR 300 R2700-2 F 322/651 | www.kuka.com Number of axes 6 Number of controlled axes 6 Volume of working envelope 56.3 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1101 kg Rated payload 300 kg Maximum payload 370 kg Maximum reach 2701 mm Protection rating (IEC 60529) IP65 / IP67 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Floor Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 5 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR 300 R2700-2 F Transformation name KR C4: KR300R2700_2 C4 FLR; KR C5: KR300R2700_2 C4 FLR Foundry robots Overpressure in the arm 0.03 MPa (0.3 bar) ±10% Compressed air Free of oil and water in accordance with ISO 8573-1:2010 (7:4:4) Compressed air supply line Air line in the cable set Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Thermal load of the wrist 10 s/min at 180 °C (453 K) Resistance Increased resistance to dust, lubricants, coolants and water vapor. Special paint finish on the robot Special paint finish on the entire robot, and an additional protective clear coat. Other ambient conditions KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) pH value 7.0 to 9.0 For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 323/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.24.2 Axis data, KR 300 R2700-2 F Axis data Motion range A1 ±185 ° A2 -140 ° / -5 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 324/651 | www.kuka.com 105 °/s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 A2 101 °/s A3 107 °/s A4 140 °/s A5 113 °/s A6 180 °/s Technical data KR QUANTEC-2 Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. Fig. 4-221: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 325/651 Technical data KR QUANTEC-2 Fig. 4-222: KR 300 R2700-2 F, working envelope, side view Fig. 4-223: KR 300 R2700-2 F, working envelope, top view 326/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4.24.3 Technical data KR QUANTEC-2 Payloads, KR 300 R2700-2 F Payloads Rated payload 300 kg Maximum payload 370 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-224: Load center of gravity and mass moment of inertia Parameter Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 327/651 Technical data KR QUANTEC-2 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! 328/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-225: Payload diagram, KR 300 R2700-2 F The KR 300 R2700-2 F is designed for a rated payload of 300 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 370 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 F Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 329/651 Technical data KR QUANTEC-2 Fig. 4-226: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-227: Flange loads Flange loads during operation F(a) 330/651 | www.kuka.com 5127 N MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F(r) 4555 N M(k) 3410 Nm M(g) 1649 Nm Technical data KR QUANTEC-2 Flange loads in the case of EMERGENCY STOP F(a) 8571 N F(r) 11250 N M(k) 6393 Nm M(g) 5225 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 331/651 Technical data KR QUANTEC-2 Fig. 4-228: Fastening of supplementary load, arm/in-line wrist, KR 300 R2700-2 F 332/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-229: Fastening of supplementary load on rotating column/link arm, KR 300 R2700-2 F 4.24.4 Foundation loads, KR 300 R2700-2 F Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 333/651 KR QUANTEC-2 Technical data The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 18164 N F(v max) 24033 N Horizontal force F(h) F(h normal) 7626 N F(h max) 20063 N Tilting moment M(k) M(k normal) 22790 Nm M(k max) 38237 Nm Torque about axis 1 M(r) 334/651 | www.kuka.com M(r normal) 7817 Nm M(r max) 17833 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-230: Foundation loads 4.25 Technical data, KR 300 R2700-2 C 4.25.1 Basic data, KR 300 R2700-2 C Basic data KR 300 R2700-2 C Number of axes 6 Number of controlled axes 6 Volume of working envelope 51.8 m³ Pose repeatability (ISO 9283) ± 0.05 mm Weight approx. 1105 kg Rated payload 300 kg Maximum payload 366 kg Maximum reach 2671 mm Protection rating (IEC 60529) IP65 Protection rating, robot wrist (IEC 60529) IP65 / IP67 Sound level < 75 dB (A) Mounting position Ceiling Footprint 754 mm x 754 mm Hole pattern: mounting surface for kinematic system S780 Permissible angle of inclination ± 0 ° Default color Base frame: black (RAL 9005); Moving parts: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C5 M6/M7 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 335/651 Technical data KR QUANTEC-2 KR 300 R2700-2 C Transformation name KR C4: KR300R2700_2 C4 CLG; KR C5: KR300R2700_2 C4 CLG The manipulator is designed in such a way that, in accordance with standard IEC 60529, no water can penetrate into electrical equipment spaces in normal operation. Water spray and corrosive additives can nevertheless lead to corrosion (rust) on uncoated parts. In this case, it is advisable to provide the equipment with corrosion protection. Corrosion does not represent a defect as defined by the standard, as long as it does not have a detrimental effect on the protection rating. The protection rating is valid in the case of compliance with the specified ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) - Cleanroom class (ISO 14644-1) - Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. During operation in the low-temperature range, frost and condensation must be avoided, as damage to property may otherwise arise. Connecting cables, KR C4 Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 - X30 Han® 16HP Data cable X21 - X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.4 "Description of the connecting cables, KR C4" Page 447). 336/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connecting cables, KR C5 Connector designation robot controller robot Cable designation Motor cable 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 - XF31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see (>>> 7.5 "Description of the connecting cables, KR C5" Page 451). 4.25.2 Axis data, KR 300 R2700-2 C Axis data Motion range A1 ±185 ° A2 -140 ° / -14 ° A3 -120 ° / 168 ° A4 ±350 ° A5 ±122.5 ° A6 ±350 ° Speed with rated payload A1 105 °/s A2 101 °/s A3 107 °/s A4 140 °/s A5 113 °/s A6 180 °/s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 337/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-231: Direction of rotation of the axes Mastering positions Mastering position A1 -25 ° A2 -100 ° A3 100 ° A4 0 ° A5 0 ° A6 0 ° Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 338/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-232: KR 300 R2700-2 C, working envelope, side view Fig. 4-233: KR 300 R2700-2 C, working envelope, top view MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 339/651 Technical data KR QUANTEC-2 4.25.3 Payloads, KR 300 R2700-2 C Payloads Rated payload 300 kg Maximum payload 366 kg Rated supplementary load, base frame 0 kg Maximum supplementary load, base frame 0 kg Rated supplementary load, rotating column 0 kg Maximum supplementary load, rotating column 300 kg Rated supplementary load, link arm 0 kg Maximum supplementary load, link arm 130 kg Rated supplementary load, arm 50 kg Maximum supplementary load, arm 150 kg Load center of gravity and mass moment of inertia Fig. 4-234: Load center of gravity and mass moment of inertia Parameter 340/651 | www.kuka.com Parameter/unit Description Mass kg Payload mass Lx, Ly, Lz mm Position of the center of mass in the reference system MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Parameter/unit Description A, B, C Orientation of the principal inertia axes Degrees • A: Rotation about the Z axis of the reference system The result is a coordinate system named CS'. • B: Rotation about the Y axis of CS' Result: CS'' • C: Rotation about the X axis of CS'' Note: A, B and C are not shown in the diagram. Mass moments of inertia: Ix kgm2 Inertia about the X axis of the main axis system Iy kgm2 Inertia about the Y axis of the main axis system Iz kgm2 Inertia about the Z axis of the main axis system Lx, Ly, Lz and A, B, C unambiguously define the main axis system: • The origin of the main axis system is the center of mass. • A characteristic feature of the main axis system is that, among other things, the maximum possible inertia occurs about one of the 3 coordinate axes. Further information is contained in the KUKA Load documentation. Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Service must be consulted beforehand. The values determined here are necessary for planning the robot application. For start-up of the robot, additional input data are required in accordance with the documentation for the system software. The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller! MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 341/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-235: Payload diagram, KR 300 R2700-2 C The KR 300 R2700-2 C is designed for a rated payload of 300 kg in order to optimize the dynamic performance of the robot. With reduced load center distances and favorable supplementary loads, a maximum payload of up to 366 kg can be mounted. The specific KUKA Load case must be verified using KUKA. For further consultation, please contact KUKA Service. Mounting flange Robot wrist type ZH300 Mounting flange standard Deviation, see figure Mounting flange (hole circle) 160 mm Thread diameter M10 Depth of engagement min. 15 mm, max. 19 mm Number of threads 11 Screw grade 10.9 Locating element 10 H7 The mounting flange is depicted with axes 4 and 6 in the zero position. 342/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-236: Mounting flange D=160 Flange loads The motion of the robot causes forces and torques to act on the mounting flange, which are transmitted to the mounted payload (e.g. tool). The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. The payload must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the tool Incorrectly dimensioned tools can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the tool for each individual case, taking the load data into consideration. • Use the specified installation equipment. Fig. 4-237: Flange loads Flange loads during operation F(a) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 4800 N www.kuka.com | 343/651 Technical data KR QUANTEC-2 F(r) 4500 N M(k) 3200 Nm M(g) 1700 Nm Flange loads in the case of EMERGENCY STOP F(a) 8700 N F(r) 12600 N M(k) 6700 Nm M(g) 5700 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagrams. 344/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 Fig. 4-238: Fastening of supplementary load, arm/in-line wrist, KR 300 R2700-2 C MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 345/651 Technical data KR QUANTEC-2 Fig. 4-239: Fastening of supplementary load on rotating column/link arm, KR 300 R2700-2 C 4.25.4 Foundation loads, KR 300 R2700-2 C Depending on the payload (e.g. tool), supplementary load and the robot’s own mass (weight), the motion of the robot generates forces and torques which are transmitted to the foundation. 346/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 The specified values refer to nominal payloads and do not include any safety factors. The actual forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. Supplementary loads on A1 (rotating column) and A2 (link arm) are not taken into consideration in the calculation of the foundation load. These must be taken into account in the vertical force (Fv). The foundation must be able to permanently withstand the forces and torques generated during normal operation. The EMERGENCY STOP values only rarely occur during the service life of the robot (emergency situations). The frequency depends on the configuration of the system. WARNING Danger to life and limb due to insufficient stability of the foundation An incorrectly dimensioned foundation can fracture and fail. Death, severe injuries or damage to property may result. • Calculate the foundation loads for each individual case. • Use the specified installation equipment. Vertical force F(v) F(v normal) 17000 N F(v max) 24900 N Horizontal force F(h) F(h normal) 8600 N F(h max) 20600 N Tilting moment M(k) M(k normal) 19800 Nm M(k max) 43200 Nm Torque about axis 1 M(r) M(r normal) 8000 Nm M(r max) 17300 Nm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 347/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 Fig. 4-240: Foundation loads 4.26 Plates and labels Plates and labels The following plates and labels (>>> Fig. 4-241) are attached to the robot. They must not be removed or rendered illegible. Illegible plates and labels must be replaced. Fig. 4-241: Location of plates and labels 348/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Item Technical data KR QUANTEC-2 Description 1 Hot surface During operation of the robot, surface temperatures may be reached that could result in burn injuries. Protective gloves must be worn! 2 Secure the axes Before exchanging any motor, secure the corresponding axis through safeguarding by suitable means/devices to protect against possible movement. The axis can move. Risk of crushing! 3 Identification plate example Content according to Machinery Directive. The QR code contains a link to product information in KUKA Xpert. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 349/651 Technical data KR QUANTEC-2 4 Transport position Before loosening the bolts of the mounting base, the robot must be in the transport position as indicated in the table. Risk of toppling! 5 Danger zone Entering the danger zone of the robot is prohibited if the robot is in operation or ready for operation. Risk of injury! 6 Counterbalancing system The system is pressurized with oil and nitrogen. Read and follow the assembly and operating instructions before commencing work on the counterbalancing system. Risk of injury! 350/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Technical data KR QUANTEC-2 7 Work on the robot Before start-up, transportation or maintenance, read and follow the assembly and operating instructions. 8 Example of identification plate for Foundry Content according to Machinery Directive. For Foundry only MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 351/651 Technical data KR QUANTEC-2 9 Mounting flange on robot wrist type IW210 The values specified on this plate apply for the installation of tools on the mounting flange of the wrist and must be observed. Mounting flange on robot wrist type IW300 The values specified on this plate apply for the installation of tools on the mounting flange of the wrist and must be observed. 4.27 REACH duty to communicate information acc. to Art. 33 As of June 2007, the Regulation (EC) 1907/2006 of the European Parliament and of the Council dated 18 December 2006 on the registration, evaluation and authorization of chemicals (REACH Regulation) is in force. Detailed REACH information can be found in the product information in KUKA Xpert. 4.28 Stopping distances and times 4.28.1 General information Information concerning the data: • The data are given for the main axes A1, A2 and A3. The main axes are the axes with the greatest deflection. • Superposed axis motions can result in longer stopping distances. • Stopping distances and stopping times in accordance with DIN EN ISO 10218-1, Annex B. • Stop categories: ‒ Stop category 0 » STOP 0 ‒ Stop category 1 » STOP 1 according to IEC 60204-1 352/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 • The values specified for Stop 0 are guide values determined by means of tests and simulation. They are average values which conform to the requirements of DIN EN ISO 10218-1. The actual stopping distances and stopping times may differ due to internal and external influences on the braking torque. It is therefore advisable to determine the exact stopping distances and stopping times where necessary under the real conditions of the actual robot application. • Measurement method The stopping distances were measured using the robot-internal measurement method. • The wear on the brakes varies depending on the operating mode, robot application and the number of STOP 0 stops triggered. It is therefore advisable to check the stopping distance at least once a year. Determination of stopping distances and times with KR C4 • The stopping distance is the angle traveled by the robot from the moment the stop signal is triggered until the robot comes to a complete standstill. • The stopping time is the time that elapses from the moment the stop signal is triggered until the robot comes to a complete standstill. Measurement method for determining the STOP 0 stopping distances and stopping times according to ISO 10218-1 with KR C5 Motion sequence • Measurement with single-axis motion (A1, A2 and A3 respectively) • Axes that are not moved are positioned in such a way that the maximum distance of the load center of gravity from the moved axis is reached. • Use the maximum motion radius of the axis to achieve as high a velocity as possible. • Trigger point at maximum velocity Measurement method 1. A safe operational stop is activated at the trigger point; this causes a STOP 0 to be triggered if the robot is moving. Start recording with trace functionality. 2. Brakes are closed. Brake closes (WDI motor status bit 2) is used as the start time of the measurement. 3. The axis comes to a standstill. Standstill is used as the end time of the measurement. As an approximation, it is also possible to carry out the measurement by means of a STOPMESS interrupt program in which the stopping distance results from the difference between the position at the trigger point ($AXIS_INT) and the position at standstill. Information concerning the data • The stopping distance is the angle covered by the axis from the Brake closes signal (WDI motor status bit 2) to complete standstill. • The stopping time is the time that elapses from the Brake closes signal (WDI motor status bit 2) until the robot comes to a complete standstill. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 353/651 Technical data KR QUANTEC-2 Technical data KR QUANTEC-2 4.28.2 Stopping distances and times, KR 120 R2700-2 and KR 120 R2700-2 F 4.28.2.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 41.21 ° A2 20.02 ° A3 22.99 ° Stopping time 354/651 | www.kuka.com A1 0.65 s A2 0.38 s A3 0.33 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.2.2 Fig. 4-242: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 355/651 Technical data KR QUANTEC-2 Fig. 4-243: Stopping times for STOP 1, axis 1 356/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.2.3 Fig. 4-244: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 357/651 Technical data KR QUANTEC-2 Fig. 4-245: Stopping times for STOP 1, axis 2 358/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.2.4 Fig. 4-246: Stopping distances for STOP 1, axis 3 Fig. 4-247: Stopping times for STOP 1, axis 3 4.28.3 Stopping distances and times, KR 120 R3100-2 and KR 120 R3100-2 F 4.28.3.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 45.57 ° A2 19.95 ° A3 20.31 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 359/651 Technical data KR QUANTEC-2 Stopping time 360/651 | www.kuka.com A1 0.77 s A2 0.46 s A3 0.35 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.3.2 Fig. 4-248: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 361/651 Technical data KR QUANTEC-2 Fig. 4-249: Stopping times for STOP 1, axis 1 362/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.3.3 Fig. 4-250: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 363/651 Technical data KR QUANTEC-2 Fig. 4-251: Stopping times for STOP 1, axis 2 364/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.3.4 Fig. 4-252: Stopping distances for STOP 1, axis 3 Fig. 4-253: Stopping times for STOP 1, axis 3 4.28.4 Stopping distances and times, KR 150 R2700-2 and KR 150 R2700-2 F 4.28.4.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 42.27 ° A2 20.58 ° A3 20.79 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 365/651 Technical data KR QUANTEC-2 Stopping time 366/651 | www.kuka.com A1 0.68 s A2 0.43 s A3 0.36 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.4.2 Fig. 4-254: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 367/651 Technical data KR QUANTEC-2 Fig. 4-255: Stopping times for STOP 1, axis 1 368/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.4.3 Fig. 4-256: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 369/651 Technical data KR QUANTEC-2 Fig. 4-257: Stopping times for STOP 1, axis 2 370/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.4.4 Fig. 4-258: Stopping distances for STOP 1, axis 3 Fig. 4-259: Stopping times for STOP 1, axis 3 4.28.5 Stopping distances and times, KR 150 R3100-2 and KR 150 R3100-2 F 4.28.5.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 41.52 ° A2 18.28 ° A3 14.86 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 371/651 Technical data KR QUANTEC-2 Stopping time 372/651 | www.kuka.com A1 0.72 s A2 0.46 s A3 0.30 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.5.2 Fig. 4-260: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 373/651 Technical data KR QUANTEC-2 Fig. 4-261: Stopping times for STOP 1, axis 1 374/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.5.3 Fig. 4-262: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 375/651 Technical data KR QUANTEC-2 Fig. 4-263: Stopping times for STOP 1, axis 2 376/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.5.4 Fig. 4-264: Stopping distances for STOP 1, axis 3 Fig. 4-265: Stopping times for STOP 1, axis 3 4.28.6 Stopping distances and times, KR 180 R2900-2 and KR 180 R2900-2 F 4.28.6.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 40.86 ° A2 18.16 ° A3 16.52 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 377/651 Technical data KR QUANTEC-2 Stopping time 378/651 | www.kuka.com A1 0.74 s A2 0.42 s A3 0.31 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.6.2 Fig. 4-266: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 379/651 Technical data KR QUANTEC-2 Fig. 4-267: Stopping times for STOP 1, axis 1 380/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.6.3 Fig. 4-268: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 381/651 Technical data KR QUANTEC-2 Fig. 4-269: Stopping times for STOP 1, axis 2 382/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.6.4 Fig. 4-270: Stopping distances for STOP 1, axis 3 Fig. 4-271: Stopping times for STOP 1, axis 3 4.28.7 Stopping distances and times, KR 210 R2700-2 and KR 210 R2700-2 F 4.28.7.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 43.00 ° A2 20.45 ° A3 16.54 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 383/651 Technical data KR QUANTEC-2 Stopping time 384/651 | www.kuka.com A1 0.77 s A2 0.49 s A3 0.38 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.7.2 Fig. 4-272: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 385/651 Technical data KR QUANTEC-2 Fig. 4-273: Stopping times for STOP 1, axis 1 386/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.7.3 Fig. 4-274: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 387/651 Technical data KR QUANTEC-2 Fig. 4-275: Stopping times for STOP 1, axis 2 388/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.7.4 Fig. 4-276: Stopping distances for STOP 1, axis 3 Fig. 4-277: Stopping times for STOP 1, axis 3 4.28.8 Stopping distances and times, KR 210 R3100-2, KR 210 R3100-2 F and KR 210 R3100-2 C 4.28.8.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 32.39 ° A2 16.74 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 389/651 Technical data KR QUANTEC-2 A3 16.27 ° Stopping time 390/651 | www.kuka.com A1 0.70 s A2 0.44 s A3 0.35 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.8.2 Fig. 4-278: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 391/651 Technical data KR QUANTEC-2 Fig. 4-279: Stopping times for STOP 1, axis 1 392/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.8.3 Fig. 4-280: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 393/651 Technical data KR QUANTEC-2 Fig. 4-281: Stopping times for STOP 1, axis 2 394/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.8.4 Fig. 4-282: Stopping distances for STOP 1, axis 3 Fig. 4-283: Stopping times for STOP 1, axis 3 4.28.9 Stopping distances and times, KR 240 R2900-2, KR 240 R2900-2 F and KR 240 R2900-2 C 4.28.9.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 32.41 ° A2 16.20 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 395/651 Technical data KR QUANTEC-2 A3 17.04 ° Stopping time 396/651 | www.kuka.com A1 0.66 s A2 0.43 s A3 0.37 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.9.2 Fig. 4-284: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 397/651 Technical data KR QUANTEC-2 Fig. 4-285: Stopping times for STOP 1, axis 1 398/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.9.3 Fig. 4-286: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 399/651 Technical data KR QUANTEC-2 Fig. 4-287: Stopping times for STOP 1, axis 2 400/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.9.4 Fig. 4-288: Stopping distances for STOP 1, axis 3 Fig. 4-289: Stopping times for STOP 1, axis 3 4.28.10 Stopping distances and times, KR 250 R2700-2, KR 250 R2700-2 F and KR 250 R2700-2 C 4.28.10.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 34.49 ° A2 14.81 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 401/651 Technical data KR QUANTEC-2 A3 20.42 ° Stopping time 402/651 | www.kuka.com A1 0.67 s A2 0.42 s A3 0.38 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Technical data 4.28.10.2 Stopping distances and stopping times, STOP 1, A1 Fig. 4-290: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 403/651 Technical data KR QUANTEC-2 Fig. 4-291: Stopping times for STOP 1, axis 1 404/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Technical data 4.28.10.3 Stopping distances and stopping times, STOP 1, A2 Fig. 4-292: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 405/651 Technical data KR QUANTEC-2 Fig. 4-293: Stopping times for STOP 1, axis 2 406/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Technical data 4.28.10.4 Stopping distances and stopping times, STOP 1, A3 Fig. 4-294: Stopping distances for STOP 1, axis 3 Fig. 4-295: Stopping times for STOP 1, axis 3 4.28.11 Stopping distances and times, KR 300 R2700-2, KR 300 R2700-2 F and KR 300 R2700-2 C 4.28.11.1 Stopping distances and stopping times, STOP 0, A1 to A3 The values for stop category 0 when a STOP 0 is triggered refer to the following configuration: • Extension l = 100% • Program override POV = 100% • Mass m = rated payload Stopping distance A1 32.24 ° A2 14.85 ° MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 407/651 Technical data KR QUANTEC-2 A3 17.46 ° Stopping time 408/651 | www.kuka.com A1 0.67 s A2 0.38 s A3 0.38 s MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A1 Technical data 4.28.11.2 Fig. 4-296: Stopping distances for STOP 1, axis 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 409/651 Technical data KR QUANTEC-2 Fig. 4-297: Stopping times for STOP 1, axis 1 410/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A2 Technical data 4.28.11.3 Fig. 4-298: Stopping distances for STOP 1, axis 2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 411/651 Technical data KR QUANTEC-2 Fig. 4-299: Stopping times for STOP 1, axis 2 412/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Stopping distances and stopping times, STOP 1, A3 Technical data 4.28.11.4 Fig. 4-300: Stopping distances for STOP 1, axis 3 Fig. 4-301: Stopping times for STOP 1, axis 3 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 413/651 Technical data KR QUANTEC-2 414/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 5 Planning 5.1 Information for planning Planning KR QUANTEC-2 In the planning and design phase, care must be taken regarding the functions or applications to be executed by the kinematic system. The following conditions can lead to premature wear. They necessitate shorter maintenance intervals and/or earlier exchange of components. In addition, the permissible operating parameters specified in the technical data must be taken into account and observed during planning. • Continuous operation near temperature limits • Continuous operation in abrasive environments • Continuous operation close to the performance limits, e.g. high rpm of an axis • Start of operation at maximum power from cold, e.g. after an idle period • High duty cycle of individual axes • Monotonous motion profiles, e.g. short, frequently recurring axis motions • Static axis positions, e.g. continuous vertical position of a wrist axis • External forces (process forces) acting on the robot If one or more of these conditions are to apply during operation of the kinematic system, KUKA Service must be consulted. If the robot reaches its corresponding operation limit or if it is operated near the limit for a period of time, the built-in monitoring functions come into effect and the robot is automatically switched off. This protective function can limit the availability of the robot system. 5.2 Mounting base with centering Description Designation Article number Weight Mounting base set S780 0000-327-118 approx. 58.5 kg The mounting base with centering is used when the kinematic system is fastened to the floor, i.e. directly on a concrete foundation. The mounting base with centering consists of: • Bedplates • Chemical anchors • Fastening elements This mounting variant requires a level and smooth surface on a concrete foundation with adequate load bearing capacity. The concrete foundation must be able to accommodate the forces occurring during operation. There must be no layers of insulation or screed between the bedplates and the concrete foundation. The minimum dimensions must be observed. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 415/651 Planning KR QUANTEC-2 Fig. 5-1: Mounting base 1 Bedplate (4x) 2 Locating pin, cylindrical 3 M24x65-8.8-A2K hexagon bolt with conical spring washer (8x) 4 Chemical anchor (12x) 5 M20 tapped hole for leveling screws (4x) 6 Locating pin, flat-sided Grade of concrete for foundations When producing foundations from concrete, observe the load-bearing capacity of the ground and the country-specific construction regulations. There must be no layers of insulation or screed between the bedplate/ bedplates and the concrete foundation. The quality of the concrete must meet the requirements of the following standard: • C20/25 according to EN 206 WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. Dimensioned drawing The following illustration (>>> Fig. 5-2) provides all the necessary information on the mounting base, together with the required foundation data. The specified foundation dimensions refer to the safe transmission of the foundation loads into the foundation and not to the stability of the foundation. 416/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Planning KR QUANTEC-2 Fig. 5-2: Mounting base, dimensioned drawing 1 Chemical anchor (12x) 2 M24x65-8.8-A2K hexagon bolt (8x) 3 Locating pin, cylindrical 4 Locating pin, flat-sided To ensure that the anchor forces are safely transmitted to the foundation, observe the dimensions for concrete foundations specified in the following illustration. Fig. 5-3: Foundation cross-section 1 Locating pin 4 Chemical anchor 2 Hexagon bolt with lock washer 5 Concrete foundation 3 Bedplate MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 417/651 Planning KR QUANTEC-2 B Min. concrete thickness in mm Concrete grade A Min. distance to edge in mm 180 Without edge reinforcement 360 With edge reinforcement ≥Ø12 290 With edge reinforcement ≥Ø12 and stirrup reinforcement at a distance of ≤100 mm 245 Without edge reinforcement 340 With edge reinforcement ≥Ø12 275 With edge reinforcement ≥Ø12 and stirrup reinforcement at a distance of ≤100 mm 230 Without edge reinforcement 300 With edge reinforcement ≥Ø12 240 With edge reinforcement ≥Ø12 and stirrup reinforcement at a distance of ≤100 mm 200 200 250 5.3 Mounting base 150 mm (optional) Description Designation Article number Weight Mounting base S780 0000-338-338 approx. 261 kg The mounting base with centering is used when the kinematic system is fastened to the floor, i.e. directly on a concrete foundation. The mounting base with centering consists of: • Bedplate • Chemical anchors • Fastening elements This mounting variant requires a level and smooth surface on a concrete foundation with adequate load bearing capacity. The concrete foundation must be able to accommodate the forces occurring during operation. There must be no layers of insulation or screed between the bedplate and the concrete foundation. The minimum dimensions must be observed. 418/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Planning KR QUANTEC-2 Fig. 5-4: Mounting base 1 Bedplate 2 Locating pin, cylindrical 3 M24x65-8.8-A2K hexagon bolt with conical spring washer (8x) 4 Chemical anchor (16x) 5 Locating pin, flat-sided 6 Orientation notch, zero position Grade of concrete for foundations When producing foundations from concrete, observe the load-bearing capacity of the ground and the country-specific construction regulations. There must be no layers of insulation or screed between the bedplate/ bedplates and the concrete foundation. The quality of the concrete must meet the requirements of the following standard: • C20/25 according to EN 206 WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. Dimensioned drawing The following illustration (>>> Fig. 5-5) provides all the necessary information on the mounting base, together with the required foundation data. The specified foundation dimensions refer to the safe transmission of the foundation loads into the foundation and not to the stability of the foundation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 419/651 Planning KR QUANTEC-2 Fig. 5-5: Mounting base, dimensioned drawing 1 Chemical anchor (16x) 2 M24x65-8.8-A2K hexagon bolt (8x) 3 Locating pin, cylindrical 4 Locating pin, flat-sided To ensure that the anchor forces are safely transmitted to the foundation, observe the dimensions for concrete foundations specified in the following illustration. Fig. 5-6: Foundation cross-section 420/651 | www.kuka.com 1 Chemical anchor (16x) 2 Bedplate MA KR QUANTEC-2 V11 | Issued: 21.08.2023 3 Concrete foundation Min. concrete thickness in mm Concrete grade A Min. distance to edge in mm 150 Without edge reinforcement 365 With edge reinforcement ≥Ø12 290 With edge reinforcement ≥Ø12 and stirrup reinforcement at a distance of ≤100 mm 235 5.4 Machine frame mounting Description Designation Article number Weight Machine frame mounting 0000-310-641 approx. 3.52 kg The machine frame mounting assembly is used when the robot is fastened on a steel structure, a booster frame (pedestal) or a KUKA linear unit. This assembly is also used if the robot is installed on the ceiling. It must be ensured that the substructure is able to withstand safely the forces occurring during operation (foundation loads). The following diagram contains all the necessary information that must be observed when preparing the mounting surface (>>> Fig. 5-7). The machine frame mounting assembly consists of: • Locating pins • Hexagon bolts with conical spring washers Fig. 5-7: Machine frame mounting 1 M24x65-8.8-A2K hexagon bolt (8x) 2 Locating pin, cylindrical 3 Locating pin, flat-sided MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 421/651 Planning KR QUANTEC-2 Planning KR QUANTEC-2 WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. Dimensioned drawing The following illustration (>>> Fig. 5-8) provides all the necessary information on machine frame mounting, together with the required foundation data. 422/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Planning KR QUANTEC-2 Fig. 5-8: Machine frame mounting, dimensioned drawing 5.5 1 Locating pin, cylindrical 3 Mounting surface 2 M24x65-8.8-A2K hexagon bolt (8x) 4 Locating pin, flat-sided Connecting cables and interfaces Connecting cables The connecting cables comprise all the cables for transferring energy and data between the robot and the robot controller. They are connected on the robot side with connectors at interface A1. Cable lengths of 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m and 50 m are available as standard. The maximum length of the connecting cables must not exceed 50 m. The maximum number of connectors is 1, i.e. a maximum of 2 connecting cables may be combined with each other. Thus MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 423/651 KR QUANTEC-2 Planning if the robot is operated on a linear unit which has its own energy supply chain, this cable must also be taken into account. For the connecting cables, an additional ground conductor is always required to provide a low-resistance connection between the robot and the control cabinet in accordance with DIN EN 60204. The ground conductor is connected via ring cable lugs. The threaded bolts for connecting the two ground conductors are located on the base frame of the robot. The following points must be observed when planning and routing the connecting cables: • The bending radius for fixed routing must not be less than 150 mm for motor cables and 60 mm for data cables. • Protect cables against exposure to mechanical stress. • Route the cables without mechanical stress – no tensile forces on the connectors. • Cables are only to be installed indoors. • Observe the permissible temperature range (fixed installation) of 263 K (-10 °C) to 343 K (+55 °C). • Route the motor cables and the data cables separately in metal ducts. If necessary, take additional measures to ensure electromagnetic compatibility (EMC). CAUTION Risk of injury due to tripping hazards Improper installation of cables can cause tripping hazards. Injuries or damage to property may result. • The connecting cables must be installed in such a way (e.g. cable ducts) as to prevent tripping hazards. • Potential tripping hazards must be marked accordingly. Interface A1 Interface A1 is located at the rear of the base frame. 424/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Planning KR QUANTEC-2 Fig. 5-9: Interface A1 1 Data cable X31 4 Ground conductor (2x) 2 Purging air (for Foundry only) 5 External axis XP8.1 3 Motor cable X30 6 External axis XP7.1 Interface for energy supply system The robot can be equipped with an energy supply system between axis 1 and axis 2 and a second energy supply system between axis 3 and axis 6. The A1 interface required for this is located on the rear of the base frame, the A3 interface is located on the side of the arm and the interface for axis 6 is located on the robot tool. Depending on the application, the interfaces differ in design and scope. They can be equipped, for example, with connections for cables and hoses. Detailed information on the connector pin allocation, threaded unions, etc. is given in separate documentation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 425/651 Planning KR QUANTEC-2 426/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 6 Transportation 6.1 Transporting the robot Transportation KR QUANTEC-2 Description Move the robot into its transport position each time it is transported. It must be ensured that the robot is stable while it is being transported. The robot must remain in its transport position until it has been fastened in position. Before the robot is lifted, it must be ensured that it is free from obstructions. Remove all transport safeguards, such as nails and screws, in advance. First remove any rust or adhesive on contact surfaces. Avoid vibrations and impacts during transportation in order to prevent damage to the manipulator. Transport position The robot must be in the transport position before it can be transported. The robot is in the transport position when the axes are in the following positions: Transport position A1 0 ° A2 -137 ° A3 160 ° A4 0 ° A5 -105 ° A6 0 ° Fig. 6-1: Transport position Transport dimensions The transportation dimensions (>>> Fig. 6-2) for the robot can be noted from the following diagram. The position of the center of gravity and the weight vary according to the specific configuration and the position of MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 427/651 KR QUANTEC-2 Transportation axes 2 and 3. The specified dimensions refer to the robot without equipment. Fig. 6-2: Transport dimensions 1 Center of gravity 2 Fork slots Transport dimensions and centers of gravity in mm: Robot KR 120 R2700-2 A B C D E SX SY SZ 1785 1614 825 555 530 -17 -62 763 1921 1798 972 555 530 -42 -65 811 1785 1614 825 555 530 -17 -62 763 1921 1798 972 555 530 -42 -65 811 1921 1614 970 555 530 -65 -65 813 1785 1614 825 555 530 -17 -62 763 KR 120 R2700-2 F KR 120 R3100-2 KR 120 R3100-2 F KR 150 R2700-2 KR 150 R2700-2 F KR 150 R3100-2 KR 150 R3100-2 F KR 180 R2900-2 KR 180 R2900-2 F KR 210 R2700-2 KR 210 R2700-2 F 428/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Robot KR 210 R3100-2 A B C D E SX SY SZ 1921 1798 972 555 530 -41 -64 811 1921 1614 970 555 530 -65 -65 813 1785 1614 825 555 530 -15 -61 763 1785 1614 825 555 530 -15 -61 763 KR 210 R3100-2 F KR 210 R3100-2 C KR 240 R2900-2 KR 240 R2900-2 F KR 240 R2900-2 C KR 250 R2700-2 KR 250 R2700-2 F KR 250 R2700-2 C KR 300 R2700-2 KR 300 R2700-2 F KR 300 R2700-2 C Transportation The robot can be transported by fork lift truck or using lifting tackle (optional). WARNING Danger to life and limb due to non-authorized handling equipment If unsuitable handling equipment is used, the robot may topple or be damaged during transportation. Death, severe injuries or damage to property may result. • Only use authorized handling equipment with a sufficient load-bearing capacity. • Only transport the robot in the manner specified here. Transportation by fork lift truck For transport by fork lift truck (>>> Fig. 6-3), four fork slots are mounted on the base frame. The robot can be picked up by the fork lift truck from the front and rear. The base frame must not be damaged when inserting the forks into the fork slots. The fork lift truck must have a minimum payload capacity of 2.0 t and an adequate fork length. Ceiling-mounted robots can only be picked up by a fork lift truck. NOTICE Damage to property due to overloading of the fork slots Overloading the fork slots during transportation can cause damage to property. • Avoid overloading the fork slots through undue inward or outward movement of hydraulically adjustable forks of the fork lift truck. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 429/651 Transportation KR QUANTEC-2 Transportation KR QUANTEC-2 Fig. 6-3: Transportation by fork lift truck Transportation with lifting tackle (optional) Designation Article number Weight Lifting tackle 0000-342-903 approx. 6.8 kg The robot can also be transported using a crane and lifting tackle (optional) (>>> Fig. 6-4). For this, it must be in the transport position. The lifting tackle (optional) is attached to the 2 front fork slots and the rotating column. All the legs must be routed as shown in the following illustration so that the robot is not damaged. Installed tools and items of equipment can cause undesirable shifts in the center of gravity. Items of equipment, especially energy supply systems, must be removed to the extent necessary to avoid them being damaged by the legs of the lifting tackle during transportation. Fig. 6-4: Transportation using lifting tackle 1 Lifting tackle assembly 2 Leg G1 3 Leg G3 4 Fork slot 5 Attachment point for swivel 6 Leg G2 All the legs are labeled. Leg G3 is provided with an adjustable chain which must be adjusted so that the robot is suspended vertically from the crane. If necessary, the robot must be set down again and the chain readjusted. Leg G3 must be slipped around the mount for the counterbalancing system on the rotating column. It must not subject the 430/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 adjacent counterbalancing system to any load. The returning strap of leg G3 must be placed next to the cable set support bracket as depicted. Fig. 6-5: Lifting tackle, leg G3 1 Chain 2 Leg G3 3 Cable set support bracket 4 Counterbalancing system 5 Counterbalancing system mount on rotating column WARNING Risk of injury during transportation The robot may tip during transportation. Death, severe injuries or damage to property may result. • When transporting the robot using lifting tackle (optional) / rope sling, care must be exercised to prevent it from tipping. • If necessary, additional safeguarding measures must be taken. • It is forbidden to pick up the robot in any other way using a crane! Transport safeguard A transport safeguard is available if the robot is transported by truck, for example. The robot can be tied down by means of a lashing belt. Care must be taken to position the lashing belt over the transport safeguard. The lashing belt must not be placed over the motor or other robot components and thus subjected to a load. Damage to property may otherwise result. The transport safeguard and fork slots can be removed for operation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 431/651 Transportation KR QUANTEC-2 Transportation KR QUANTEC-2 Fig. 6-6: Transport safeguard 432/651 | www.kuka.com 1 Transport safeguard 2 Fork slot MA KR QUANTEC-2 V11 | Issued: 21.08.2023 7 Start-up and recommissioning The procedure for start-up and recommissioning depends on the type of fastening and installation position of the manipulator. Description Robot installation Information Installation position: floor and mounting Starting up floor-mounted robots base (mounting base) (>>> 7.1 "Starting up floor-mounted robots (mounting base)" Page 433) Robot installation Installation position: floor and mounting Starting up floor-mounted robots base 150 mm (option) (mounting base 150 mm option) (>>> 7.2 "Starting up floor-mounted robots (optional 150 mm mounting base)" Page 438) Robot installation Installation position: floor, ceiling and machine frame mounting Starting up floor-mounted robots (machine frame mounting) (>>> 7.3 "Starting up robots (machine frame mounting)" Page 443) 7.1 Starting up floor-mounted robots (mounting base) Description The mounting base is used for installing robots on a foundation. They are fastened to a suitable concrete foundation using a bedplate / foundation slats and chemical anchors. This description is valid for the installation of floor-mounted robots with the mounting variant “mounting base”. If the surface of the concrete foundation is not sufficiently smooth and even, the differences must be evened out with a suitable leveling compound. When using chemical anchors, use only resin cartridges and anchors from the same manufacturer. No diamond tools or core drills may be used for drilling the anchor holes; for preference, drilling tools supplied by the anchor manufacturer are to be used. Observe also the manufacturer’s instructions for the use of chemical anchors. The installation and start-up of the robot controller, the tools mounted and the applications are not described here. Equipment The following equipment is required: Designation Article number Lifting tackle/rope sling with sufficient load-bearing capacity 0000-342-903 Crane with sufficient load-bearing capacity - Fork lift truck with sufficient load-bearing capacity - Drill with a ø 18 mm bit - Setting tool approved by the anchor manufacturer - MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 433/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 to 100 Nm - Torque wrench min. 400 to 700 Nm - Material The following material is required: Designation Article number Quantity Mounting base set S780 0000-327-118 1 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • • • • • • • • The installation site is accessible with a crane or fork lift truck. The robot is in the transport position. The substructure has been checked for sufficient safety. The concrete foundation must have the required dimensions and cross-section. The surface of the foundation must be smooth and even. Have the leveling compound readily at hand. Any tools or other system components which would hinder the work have been removed. The connecting cables and ground conductors are routed to the robot and installed. Work safety WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. 434/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 WARNING Danger to life and limb due to non-authorized handling equipment If unsuitable handling equipment is used, the robot may topple or be damaged during transportation. Death, severe injuries or damage to property may result. • Only use authorized handling equipment with a sufficient load-bearing capacity. • Only transport the robot in the manner specified here. WARNING Risk of injury during transportation The robot may tip during transportation. Death, severe injuries or damage to property may result. • When transporting the robot using lifting tackle (optional) / rope sling, care must be exercised to prevent it from tipping. • If necessary, additional safeguarding measures must be taken. • It is forbidden to pick up the robot in any other way using a crane! CAUTION Risk of injury due to tripping hazards Improper installation of cables can cause tripping hazards. Injuries or damage to property may result. • The connecting cables must be installed in such a way (e.g. cable ducts) as to prevent tripping hazards. • Potential tripping hazards must be marked accordingly. WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. 7.1.1 Installing the robot with mounting base Procedure 1. Clean the concrete foundation. 2. Screw 2 locating pins into the bedplates with 1 M8x55-8.8 Allen screw each and check that they are fitted securely (>>> Fig. 7-1). 3. Lift the robot with the crane or fork lift truck and move it to the installation site. 4. Clean the lower mounting surface on the robot. 5. Fasten the 4 bedplates to the robot using 2 M24x65-8.8 hexagon bolts with conical spring washers for each one. Ensure that an entirely vertical position is maintained in order to prevent damage to the locating pins. 6. Tighten 8 M24x65-8.8 hexagon bolts with torque wrench. Increase the tightening torque to the specified value in several stages. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 435/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 Fig. 7-1: Mounting base 1 Bedplate (4x) 2 Locating pin, cylindrical 3 M24x65-8.8-A2K hexagon bolt with conical spring washer (8x) 4 Chemical anchor (12x) 5 M20 tapped hole for leveling screws (4x) 6 Locating pin, flat-sided 7. Determine the position of the robot on the mounting base in relation to the working envelope. 8. Set the robot down on the mounting base in its installation position. 9. Check the surface of the concrete foundation against the specified value: • If the surface is sufficiently smooth and even, continue with step 15. • If the surface is not sufficiently smooth and even, continue with step 10. 10. 11. 12. 13. 14. 15. 436/651 | www.kuka.com If the evenness of the foundation is outside the specified tolerances, this can cause strain or result in loosening of the mounting base. Lift robot with crane or fork lift truck. Apply sufficient leveling compound to the underside of the bedplates (toothed spatula). The area under the hexagon bolt for robot fastening must be kept free from leveling compound. Set down the robot and align horizontally with leveling screws if necessary. Remove excess leveling compound. The maximum height of the leveling compound must not be exceeded. Observe the manufacturer’s specifications. Allow the leveling compound to set in accordance with the manufacturer’s specifications. Drill 12 anchor holes in accordance with the manufacturer’s specifications and fit the anchors as specified in the instructions for use. The instructions for use are enclosed with the anchors and must be followed precisely. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 7.1.2 Connecting the connecting cables Procedure 1. Fasten the ground conductor between the robot controller and the robot to the ground conductor connection with 1 M8 hexagon nut including conical spring washer; tightening torque MA= 23.0 Nm. 2. Fasten the ground conductor between the system component and the robot to the ground conductor connection with 1 M8 hexagon nut including conical spring washer; tightening torque MA= 23.0 Nm. 3. Connect data cable: • KR C4: X31 • KR C5: XF31 When connecting the data cable connectors, it must be ensured that the connector is locked correctly on the robot. Correct locking is achieved by closing the clip (>>> Fig. 7-2). 4. Connect motor cable: • KR C4: X30 • KR C5: XD30 Push on the motor cable connector, insert 4 fastening screws and tighten with tightening torque MA= 3.0 Nm. 5. Check the equipotential bonding in accordance with VDE 0100 and EN 60204-1. Further information is contained in the operating and assembly instructions of the robot controller. Fig. 7-2: Connecting the connecting cables 7.1.3 1 Data cable 3 Fastening screw (4x) 2 Motor cable 4 Ground conductor Concluding work The following concluding work must be carried out: • Mount tooling, if present. • Start up the robot system in accordance with the chapter “Start-up and recommissioning” in the operating instructions for the robot controller. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 437/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 • Put the robot system into operation in accordance with the documentation for the system software. CAUTION Sudden escape of air in the counterbalancing system Following storage of the manipulator, an air cushion can build up in the counterbalancing system. If the air escapes suddenly, this can cause the protective cap of the vent valve to shoot off in exceptional cases. Injuries may result. 1. Remove the protective cap of the counterbalancing system vent valve. 2. Maintain a safe distance. 3. Move A2 by ±30°. 4. Refit the protective cap. 7.2 Starting up floor-mounted robots (optional 150 mm mounting base) Description The mounting base is used for installing robots on a foundation. They are fastened to a suitable concrete foundation using a bedplate / foundation slats and chemical anchors. This description is valid for the installation of floor-mounted robots with the mounting variant “mounting base”. If the surface of the concrete foundation is not sufficiently smooth and even, the differences must be evened out with a suitable leveling compound. When using chemical anchors, use only resin cartridges and anchors from the same manufacturer. No diamond tools or core drills may be used for drilling the anchor holes; for preference, drilling tools supplied by the anchor manufacturer are to be used. Observe also the manufacturer’s instructions for the use of chemical anchors. The installation and start-up of the robot controller, the tools mounted and the applications are not described here. Equipment The following equipment is required: 438/651 | www.kuka.com Designation Article number Lifting tackle/rope sling with sufficient load-bearing capacity 0000-342-903 Crane with sufficient load-bearing capacity - Fork lift truck with sufficient load-bearing capacity - Drill with a ø 18 mm bit - Setting tool approved by the anchor manufacturer - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 to 100 Nm - MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Designation Article number Torque wrench min. 400 to 700 Nm - Material The following material is required: Designation Article number Quantity Mounting base S780 0000-338-338 1 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • • • • • • • • The installation site is accessible with a crane or fork lift truck. The robot is in the transport position. The substructure has been checked for sufficient safety. The concrete foundation must have the required dimensions and cross-section. The surface of the foundation must be smooth and even. Have the leveling compound readily at hand. Any tools or other system components which would hinder the work have been removed. The connecting cables and ground conductors are routed to the robot and installed. Work safety WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 439/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 WARNING Danger to life and limb due to non-authorized handling equipment If unsuitable handling equipment is used, the robot may topple or be damaged during transportation. Death, severe injuries or damage to property may result. • Only use authorized handling equipment with a sufficient load-bearing capacity. • Only transport the robot in the manner specified here. WARNING Risk of injury during transportation The robot may tip during transportation. Death, severe injuries or damage to property may result. • When transporting the robot using lifting tackle (optional) / rope sling, care must be exercised to prevent it from tipping. • If necessary, additional safeguarding measures must be taken. • It is forbidden to pick up the robot in any other way using a crane! CAUTION Risk of injury due to tripping hazards Improper installation of cables can cause tripping hazards. Injuries or damage to property may result. • The connecting cables must be installed in such a way (e.g. cable ducts) as to prevent tripping hazards. • Potential tripping hazards must be marked accordingly. WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. 7.2.1 Installing the robot with mounting base 150 mm (optional) Procedure 1. Clean the concrete foundation. 2. Screw 2 locating pins into the bedplate with 1 M8x55-8.8 Allen screw each and check that they are fitted securely (>>> Fig. 7-3). 3. Lift the robot with the crane or fork lift truck and move it to the installation site. 4. Clean the lower mounting surface on the robot. 5. Fasten the bedplate to the robot using 8 M24x65-8.8 hexagon bolts with conical spring washers. Ensure that an entirely vertical position is maintained in order to prevent damage to the locating pins. 6. Tighten 8 M24x65-8.8 hexagon bolts with torque wrench. Increase the tightening torque to the specified value in several stages. 440/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Start-up and recommissioning KR QUANTEC-2 Fig. 7-3: Mounting base 1 Bedplate 2 Locating pin, cylindrical 3 M24x65-8.8-A2K hexagon bolt with conical spring washer (8x) 4 Chemical anchor (16x) 5 Locating pin, flat-sided 6 Orientation notch, zero position 7. Determine the position of the robot on the mounting base in relation to the working envelope. 8. Set the robot down on the mounting base in its installation position. 9. Check the surface of the concrete foundation against the specified value: • If the surface is sufficiently smooth and even, continue with step 15. • If the surface is not sufficiently smooth and even, continue with step 10. 10. 11. 12. 13. 14. 15. If the evenness of the foundation is outside the specified tolerances, this can cause strain or result in loosening of the mounting base. Lift robot with crane or fork lift truck. Apply sufficient leveling compound to the underside of the bedplate (toothed spatula). The area under the hexagon bolt for robot fastening must be kept free from leveling compound. Set down the robot and align horizontally with leveling screws if necessary. Remove excess leveling compound. The maximum height of the leveling compound must not be exceeded. Observe the manufacturer’s specifications. Allow the leveling compound to set in accordance with the manufacturer’s specifications. Drill 16 anchor holes in accordance with the manufacturer’s specifications and fit the anchors as specified in the instructions for use. The instructions for use are enclosed with the anchors and must be followed precisely. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 441/651 Start-up and recommissioning KR QUANTEC-2 7.2.2 Connecting the connecting cables Procedure 1. Fasten the ground conductor between the robot controller and the robot to the ground conductor connection with 1 M8 hexagon nut including conical spring washer; tightening torque MA= 23.0 Nm. 2. Fasten the ground conductor between the system component and the robot to the ground conductor connection with 1 M8 hexagon nut including conical spring washer; tightening torque MA= 23.0 Nm. 3. Connect data cable: • KR C4: X31 • KR C5: XF31 When connecting the data cable connectors, it must be ensured that the connector is locked correctly on the robot. Correct locking is achieved by closing the clip (>>> Fig. 7-4). 4. Connect motor cable: • KR C4: X30 • KR C5: XD30 Push on the motor cable connector, insert 4 fastening screws and tighten with tightening torque MA= 3.0 Nm. 5. Check the equipotential bonding in accordance with VDE 0100 and EN 60204-1. Further information is contained in the operating and assembly instructions of the robot controller. Fig. 7-4: Connecting the connecting cables 7.2.3 1 Data cable 3 Fastening screw (4x) 2 Motor cable 4 Ground conductor Concluding work The following concluding work must be carried out: • Mount tooling, if present. • Start up the robot system in accordance with the chapter “Start-up and recommissioning” in the operating instructions for the robot controller. 442/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 • Put the robot system into operation in accordance with the documentation for the system software. CAUTION Sudden escape of air in the counterbalancing system Following storage of the manipulator, an air cushion can build up in the counterbalancing system. If the air escapes suddenly, this can cause the protective cap of the vent valve to shoot off in exceptional cases. Injuries may result. 1. Remove the protective cap of the counterbalancing system vent valve. 2. Maintain a safe distance. 3. Move A2 by ±30°. 4. Refit the protective cap. 7.3 Starting up robots (machine frame mounting) Description The machine frame mounting is used for installing robots on a steel structure prepared by the customer. Fastening is carried out using 8 hexagon bolts with conical spring washers. A cylindrical pin and a flat-sided pin are provided to ensure correct positioning. This description is valid for the installation of floor and ceiling-mounted robots with the mounting variant “machine frame mounting”. The ceiling-mounted installation is analogous to installation of the floormounted robot. The installation and start-up of the robot controller, the tools mounted and the applications are not described here. Equipment The following equipment is required: Designation Article number Lifting tackle/rope sling with sufficient load-bearing capacity 0000-342-903 Crane with sufficient load-bearing capacity - Fork lift truck with sufficient load-bearing capacity - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 2 to 20 Nm - Torque wrench min. 400 to 700 Nm - Material The following material is required: Designation Article number Quantity Machine frame mounting 0000-310-641 1 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 443/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • • • • • The installation site is accessible with a crane or fork lift truck. The robot is in the transport position. The substructure has been checked for sufficient safety. The mounting surface has been prepared. Any tools or other system components which would hinder the work have been removed. • The connecting cables and ground conductors are routed to the robot and installed. Work safety WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. WARNING Danger to life and limb due to non-authorized handling equipment If unsuitable handling equipment is used, the robot may topple or be damaged during transportation. Death, severe injuries or damage to property may result. • Only use authorized handling equipment with a sufficient load-bearing capacity. • Only transport the robot in the manner specified here. WARNING Risk of injury during transportation The robot may tip during transportation. Death, severe injuries or damage to property may result. • When transporting the robot using lifting tackle (optional) / rope sling, care must be exercised to prevent it from tipping. • If necessary, additional safeguarding measures must be taken. • It is forbidden to pick up the robot in any other way using a crane! 444/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 CAUTION Risk of injury due to tripping hazards Improper installation of cables can cause tripping hazards. Injuries or damage to property may result. • The connecting cables must be installed in such a way (e.g. cable ducts) as to prevent tripping hazards. • Potential tripping hazards must be marked accordingly. WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. 7.3.1 Installing the robot with the machine frame mounting assembly Procedure 1. Clean the mounting surface. 2. Check the hole pattern on the mounting surface. 3. Screw 2 locating pins into the mounting surface and check that they are fitted securely. 4. Lift the robot with the crane or fork lift truck and move it to the installation site. 5. Clean the lower mounting surface on the robot. 6. Lower the robot vertically onto the mounting surface. Ensure that an entirely vertical position is maintained in order to prevent damage to the locating pins. 7. Insert 8 M24x65-8.8 hexagon bolts together with conical spring washers. 8. Tighten the 8 M24x65-8.8 hexagon bolts with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 445/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 Fig. 7-5: Machine frame mounting 1 M24x65-8.8-A2K hexagon bolt (8x) 2 Locating pin, cylindrical 3 Locating pin, flat-sided 7.3.2 Connecting the connecting cables Procedure 1. Fasten the ground conductor between the robot controller and the robot to the ground conductor connection with 1 M8 hexagon nut including conical spring washer; tightening torque MA= 23.0 Nm. 2. Fasten the ground conductor between the system component and the robot to the ground conductor connection with 1 M8 hexagon nut including conical spring washer; tightening torque MA= 23.0 Nm. 3. Connect data cable: • KR C4: X31 • KR C5: XF31 When connecting the data cable connectors, it must be ensured that the connector is locked correctly on the robot. Correct locking is achieved by closing the clip (>>> Fig. 7-6). 4. Connect motor cable: • KR C4: X30 • KR C5: XD30 Push on the motor cable connector, insert 4 fastening screws and tighten with tightening torque MA= 3.0 Nm. 5. Check the equipotential bonding in accordance with VDE 0100 and EN 60204-1. Further information is contained in the operating and assembly instructions of the robot controller. 446/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Start-up and recommissioning KR QUANTEC-2 Fig. 7-6: Connecting the connecting cables 7.3.3 1 Data cable 3 Fastening screw (4x) 2 Motor cable 4 Ground conductor Concluding work The following concluding work must be carried out: • Mount tooling, if present. • Start up the robot system in accordance with the chapter “Start-up and recommissioning” in the operating instructions for the robot controller. • Put the robot system into operation in accordance with the documentation for the system software. CAUTION Sudden escape of air in the counterbalancing system Following storage of the manipulator, an air cushion can build up in the counterbalancing system. If the air escapes suddenly, this can cause the protective cap of the vent valve to shoot off in exceptional cases. Injuries may result. 1. Remove the protective cap of the counterbalancing system vent valve. 2. Maintain a safe distance. 3. Move A2 by ±30°. 4. Refit the protective cap. 7.4 Description of the connecting cables, KR C4 Configuration The connecting cables are used to transfer power and data between the robot controller and the robot. The connecting cables comprise: • Motor cable • Data cable MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 447/651 Start-up and recommissioning KR QUANTEC-2 Interface Cable designation Connector designation robot controller robot Interface with robot Motor cable X20 – X30 Han® 16HP Data cable X21 – X31 Han® 3A Q12 Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug at both ends Standard connecting cable Fig. 7-7: Connecting cables, overview 7.4.1 Description of the Motor cable Cable overview Fig. 7-8: Motor cable 1 X20 2 X30 Connector pin allocation Connector pin allocation X20 Connector pin allocation X30 The contact assignment on the connector side is shown in each case. 448/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Wiring diagram X20 Pin Description X30 Pin a1 Motor M1 U 1 2 Motor M1 V 2 3 Motor M1 W 3 11 Brake + 19 12 Brake - 20 b1 Motor M2 U 4 2 Motor M2 V 5 3 Motor M2 W 6 11 Brake + 21 12 Brake - 22 c1 Motor M3 U 7 2 Motor M3 V 8 3 Motor M3 W 9 11 Brake + 23 12 Brake - 24 d1 Motor M4 U 10 4 Motor M4 V 11 6 Motor M4 W 12 3 Brake + 25 5 Brake - 26 e1 Motor M5 U 13 4 Motor M5 V 14 6 Motor M5 W 15 3 Brake + 27 5 Brake - 28 f1 Motor M5 U 16 4 Motor M5 V 17 6 Motor M5 W 18 3 Brake + 29 5 Brake - 30 Ground conductor Housing Shield, all pins MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Housing www.kuka.com | 449/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 7.4.2 Description of the Data cable Cable overview Fig. 7-9: Data cable 1 X21 2 X31 Connector pin allocation Connector pin allocation X21 Connector pin allocation X31 The contact assignment on the connector side is shown in each case. Wiring diagram 450/651 | www.kuka.com X21 Pin Description X31 Pin 9 TPFO_P 9 11 TPFO_N 11 Housing Shield, pin 9, pin 11 Housing 10 TPFI_P 10 12 TPFI_N 12 Housing Shield, pin 10, pin 12 Housing 3 Ground 3 2 24 V/PS1 with battery back-up 2 Housing Shield, all pins Housing MA KR QUANTEC-2 V11 | Issued: 21.08.2023 7.4.3 Start-up and recommissioning KR QUANTEC-2 Description of the ground conductor Fig. 7-10: Connecting cable, ground conductor 7.5 1 Ground conductor 6 Conical spring washer 2 Hexagon nut 7 Robot 3 Conical spring washer 8 Setscrew 4 2x plain washer 9 Ground conductor connection Ring cable lug 5 Hexagon nut 10 Ground sign Description of the connecting cables, KR C5 Configuration The connecting cables are used to transfer power and data between the robot controller and the robot. The connecting cables comprise: • Motor cable • Data cable Interface Cable designation Motor cable Connector designation robot controller robot 6 motor connectors: XD20.1 … XD20.6 - XD30 Interface with robot Han® 16HP 2 brake connectors: XD10.1, XD10.2 - XD30 Data cable XF21 – XF31 Ground conductor / equipotential bonding 16 mm2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Han® 3A Q12 M8 ring cable lug at both ends www.kuka.com | 451/651 Start-up and recommissioning KR QUANTEC-2 Standard connecting cable Fig. 7-11: Connecting cables, overview 7.5.1 Description of the Motor cable Cable overview Fig. 7-12: Motor cable 452/651 | www.kuka.com 1 XD20.x / XD10.x 2 XD30 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connector pin allocation Connector pin allocation XD20.x / XD10.x Connector pin allocation XD30 The contact assignment on the connector side is shown in each case. Wiring diagram XD20.x / XD10.x Pin Description XD30 Pin XD20.1 / 1 M1:U 1 XD20.1 / 2 M1:V 2 XD20.1 / 3 M1:W 3 XD20.1 / PE PE PE1 XD10.1 / B:1 M1_br_+ XD10.1 / A:1 M1_br_GND 20 Housing Shield B1, A1 Housing XD20.2 / 1 M2:U 4 XD20.2 / 2 M2:V 5 XD20.2 / 3 M2:W 6 XD10.1 / B:2 M2_br_+ XD10.1 / A:2 M2_br_GND 22 Housing Shield B2, A2 Housing XD20.3 / 1 M3:U 7 XD20.3 / 2 M3:V 8 XD20.3 / 3 M3:W 9 XD10.1 / B:3 M3_br_+ XD10.1 / A:3 M3_br_GND 24 Housing Shield B3, A3 Housing XD20.4 / 1 M4:U 10 XD20.4 / 2 M4:V 11 XD20.4 / 3 M4:W 12 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 twisted twisted twisted 19 21 23 www.kuka.com | 453/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 XD20.x / XD10.x Pin 7.5.2 Description XD30 Pin XD20.4 / PE PE PE2 XD10.2 / B:2 M4_br_+ XD10.2 / A:1 M4_br_GND 26 Housing Shield B2, A1 Housing XD20.5 / 1 M5:U 13 XD20.5 / 2 M5:V 14 XD20.5 / 3 M5:W 15 XD10.2 / A:2 M5_br_+ XD10.2 / A:1 M5_br_GND 28 Housing Shield A2, A1 Housing XD20.6 / 1 M6:U 16 XD20.6 / 2 M6:V 17 XD20.6 / 3 M6:W 18 XD10.2 / A:3 M6_br_+ XD10.2 / A:4 M6_br_GND 30 Housing Shield A3, A4 Housing Housing Overall shield twisted twisted twisted 25 27 29 Description of the Data cable Cable overview Fig. 7-13: Data cable 454/651 | www.kuka.com 1 XF21 2 XF31 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Connector pin allocation Connector pin allocation XF21 Connector pin allocation XF31 The contact assignment on the connector side is shown in each case. Wiring diagram 7.5.3 XF21 Pin Description XF31 Pin 5 PSU_27V_IO 5 6 PSU_GND 6 7 PSU_27V_POS 2 8 PSU_GND 3 1 Rx+ 10 2 Rx- 12 3 Tx+ 9 4 Tx- 11 Housing Shield, all pins Housing Description of the ground conductor Fig. 7-14: Connecting cable, ground conductor 1 Ground conductor 6 Conical spring washer 2 Hexagon nut 7 Robot 3 Conical spring washer 8 Setscrew MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 455/651 Start-up and recommissioning KR QUANTEC-2 Start-up and recommissioning KR QUANTEC-2 456/651 | www.kuka.com 4 2x plain washer 9 Ground conductor connection Ring cable lug 5 Hexagon nut 10 Ground sign MA KR QUANTEC-2 V11 | Issued: 21.08.2023 8 Maintenance Only maintenance and repair work described in this document may be performed. Work that exceeds this scope may only be carried out by personnel specially trained by KUKA. Information about KUKA College and its training program can be found at college.kuka.com or can be obtained directly from our subsidiaries. In the case of support and repair services provided by KUKA, KUKA Service must be informed in advance about potential contamination or hazards. Non-compliance nullifies warranty and liability claims. 8.1 Maintenance overview Description The maintenance intervals given in the tables are valid for the operating conditions specified in the technical data (>>> 4 "Technical data" Page 39). KUKA Deutschland must be consulted in the event of deviations in working conditions or the use of special functions or applications. Further information can be found in the section “Information for planning” (>>> 5.1 "Information for planning" Page 415). A general inspection of the manipulator is recommended after 7 years or upon modifying its use. Please contact KUKA Service for this. If the robot is fitted with a KUKA energy supply system (optional), additional maintenance work must be carried out. NOTICE Only auxiliary substances and consumables approved by KUKA Deutschland GmbH may be used. Non-approved auxiliary substances and consumables may cause premature wear and failure of assemblies. Precondition • The maintenance points must be freely accessible. • Remove the tools and any additional items of equipment if they impede maintenance work. WARNING Danger to life and limb due to unintended robot motions When carrying out the following work, the robot must be moved several times between the individual work steps. Unintentional movements of the robot can cause death, serious injury or material damage. • While work is being carried out on the robot, it must always be secured by actuating the EMERGENCY STOP device. • If work is carried out on an operational robot that is switched on, the robot must only be moved at reduced velocity. It must be possible to stop the robot at any time by actuating an EMERGENCY STOP device. Operation must be limited to what is absolutely necessary. • Warn all persons concerned before switching on and moving the robot. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 457/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 If oil temperatures of more than 60 °C (333 K) are reached during operation, shorter maintenance intervals must be observed. Please contact KUKA Service for this. 8.1.1 Maintenance table Maintenance symbols The overview may contain maintenance symbols that are not relevant for the maintenance work on this product. The maintenance illustrations provide an overview of the relevant maintenance work. Oil change Lubricate with grease gun Lubricate with brush Lubricate with spray grease Tighten screw/nut Check component, visual inspection Clean component Exchange battery Exchange component Check toothed belt tension 458/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-1: Maintenance diagram Maintenance table, KR QUANTEC-2, standard and C variants Interval Item Task Auxiliary substances and consumables 100 h 9 Check bolts; MA 640 Nm - Once only, after start-up (installation) 5000 h or 1 year at the latest 1) 5 Counterbalancing system bearing on link arm, lubricate. Grease lubricating nipples in middle position and at plus and minus end positions (1 nipple in each case). LGEP 2 lubricating grease 5000 h or 1 year at the latest 1) 7 Counterbalancing system bearing on rotating column, lubricate. Grease lubricating nipples in middle position and at plus and minus end positions (1 nipple in each case). LGEP 2 lubricating grease 5000 h 6 Counterbalancing system, check pres- Hyspin ZZ 46 hydraulic oil sure (>>> 8.8 "Checking the counterbalancing system" Page 485) 20000 h or 5 years at the latest 1 Perform oil change on gear units A5/A6. (>>> 8.7 "Oil change in A5/A6" Page 480) Optigear Synt. ALR 150 20000 h or 5 years at the latest 2 Perform oil change on gear unit A4. (>>> 8.6 "Oil change in A4" Page 476) Optigear Synt. ALR 150 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 10 cm³ 10 cm³ Initial filling quantity: 1.40 l for in-line wrist type ZH210 and ZH210 F 1.90 l for in-line wrist type ZH300 and ZH300 F Initial filling quantity: 2.10 l www.kuka.com | 459/651 Maintenance KR QUANTEC-2 Interval Item Task Auxiliary substances and consumables 20000 h or 5 years at the latest 3 Perform oil change on gear unit A3. (>>> 8.5 "Oil change in A3" Page 472) Optigear Synt. ALR 150 20000 h or 5 years at the latest 4 Perform oil change on gear unit A2. (>>> 8.4 "Oil change in A2" Page 468) Optigear Synt. ALR 150 20000 h or 5 years at the latest 8 Perform oil change on gear unit A1. (>>> 8.2 "Oil change in A1, floormounted robot" Page 461) (>>> 8.3 "Oil change in A1, ceilingmounted robot" Page 464) Optigear Synt. ALR 150 Exchange the counterbalancing system (>>> 8.9 "Counterbalancing system, floor, exchanging" Page 487) (>>> 8.10 "Exchanging the counterbalancing system on a ceiling-mounted robot" Page 498) - 10 years 6 Initial filling quantity: 1.40 l Initial filling quantity: 2.10 l Initial filling quantity: 5.70 l for floor-mounted robots Initial filling quantity: 8.30 l for ceiling-mounted robots 1) In the case of frequently recurring, short-distance movements, the maintenance interval is 3 000 hours. Maintenance table, KR QUANTEC-2, F variants Interval Item Task Auxiliary substances and consumables 100 h 9 Check bolts; MA 640 Nm - Once only, after start-up (installation) 2500 h or 1 year at the latest 5 2500 h or 1 year at the latest 7 2500 h 6 Counterbalancing system, check pres- Hyspin ZZ 46 hydraulic oil sure (>>> 8.8 "Checking the counterbalancing system" Page 485) 10000 h or 5 years at the latest 1 Perform oil change on gear units A5/A6. (>>> 8.7 "Oil change in A5/A6" Page 480) Optigear Synt. ALR 150 10000 h or 5 years at the latest 2 Perform oil change on gear unit A4. (>>> 8.6 "Oil change in A4" Page 476) Optigear Synt. ALR 150 460/651 | www.kuka.com Counterbalancing system bearing on link arm, lubricate. Grease lubricating nipples in middle position and at plus and minus end positions (1 nipple in each case). LGEP 2 lubricating grease Counterbalancing system bearing on rotating column, lubricate. Grease lubricating nipples in middle position and at plus and minus end positions (1 nipple in each case). LGEP 2 lubricating grease 10 cm³ 10 cm³ Initial filling quantity: 1.40 l for in-line wrist type ZH210 and ZH210 F 1.90 l for in-line wrist type ZH300 and ZH300 F Initial filling quantity: 2.10 l MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Interval Item Task Auxiliary substances and consumables 10000 h or 5 years at the latest 3 Perform oil change on gear unit A3. (>>> 8.5 "Oil change in A3" Page 472) Optigear Synt. ALR 150 10000 h or 5 years at the latest 4 Perform oil change on gear unit A2. (>>> 8.4 "Oil change in A2" Page 468) Optigear Synt. ALR 150 10000 h or 5 years at the latest 8 Perform oil change on gear unit A1. (>>> 8.2 "Oil change in A1, floormounted robot" Page 461) Optigear Synt. ALR 150 Initial filling quantity: 1.40 l Initial filling quantity: 2.10 l Initial filling quantity: 5.70 l for floor-mounted robots Initial filling quantity: 8.30 l for ceiling-mounted robots 10 years 6 Exchange the counterbalancing system (>>> 8.9 "Counterbalancing system, floor, exchanging" Page 487) - Up-to-date safety data sheets must be requested from the manufacturers of auxiliary and operating materials. Further information about the auxiliary substances and consumables used can be found under: (>>> 12.2 "Auxiliary and operating materials used" Page 636) The service life of the cable set corresponds to that of the robot, provided that programs are executed in the normal range. If, however, the programs are at the limits, the service life of the cable set is reduced and it may be necessary to exchange the cable set prematurely. 8.2 Oil change in A1, floor-mounted robot Description The following sections describe the A1 gear oil change for floor-mounted robots. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 to 100 Nm - Socket wrench set - Collection receptacle - KUKA oil pump 0000-180-812 Material The following material is required: MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 461/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 Designation Article number Quantity Optigear Synt. ALR 150 (>>> 12.2 "Auxiliary and operating materials used" Page 636) Initial filling quantity: 5.70 l Refilling quantity CAUTION The quantity of oil drained depends on the draining time and the oil temperature. The refilling quantity is the quantity of oil that was drained from the gear unit at the correct operating temperature and with the correct draining time. This oil quantity must be determined. Only this quantity of oil may be used when refilling. If less than 70 % of the specified oil quantity flows out, flush the gear unit with the determined quantity of drained oil once, then pour in the amount of oil that was drained. If less than 50% of the specified oil quantity flows out (e.g. inclined installation), the flushing operation must be repeated twice. During the flushing procedure, move the axis at jog velocity throughout the entire axis range. The oil quantities specified in the table correspond to the oil quantities in the gear unit at first filling. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Preconditions • The gear unit is at operating temperature. • The oil filler hole (magnetic screw plug) in the rotating column is freely accessible; any covers must be removed beforehand. Work safety CAUTION High oil and surface temperatures after the robot has stopped operating If the oil change is carried out immediately after the robot has stopped operating, the oil temperature and the surface temperature are liable to be high. Touching them may result in burns. • Wear protective gloves. 462/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 WARNING Danger to life and limb due to unintended robot motions Unintended robot motions may result in death, severe injuries and damage to property. • Secure the robot by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 8.2.1 Draining the gear oil from A1 Procedure 1. Place a suitable receptacle under the drain hole (>>> Fig. 8-2). 2. Unscrew the union nut from the drain hole. 3. Remove the M22x1.5 magnetic screw plug from the rotating column for venting and catch the oil as it drains out. 4. Measure the amount of oil drained and store or dispose of the used oil in accordance with the pertinent regulations. Fig. 8-2: Draining the gear oil from A1 8.2.2 1 Magnetic screw plug M22x1.5 2 Drain hole 3 Union nut 4 Collection receptacle Filling A1 with gear oil Procedure 1. Connect the oil pump to the drain hole (>>> Fig. 8-3). MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 463/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 2. Fill the specified amount of oil from below via the drain hole using the oil pump. 3. Clean the magnetic screw plug and check the sealing element; exchange the magnetic screw plug if damaged. 4. Insert and tighten the M22x1.5 magnetic screw plug; MA= 25 Nm. 5. Remove the oil pump from the drain hole. 6. Screw the union nut onto the drain hole and tighten; MA = 45 Nm, then check for leaks. Fig. 8-3: Filling A1 with gear oil 8.2.3 1 Magnetic screw plug M22x1.5 2 Drain hole 3 Union nut 4 Oil pump Concluding work The following concluding work must be carried out: • Remove oil residue. • Visual inspection, check for leaks. • Run the program in T1 mode and look out for irregularities. 8.3 Oil change in A1, ceiling-mounted robot Description The following sections describe the A1 gear oil change on a ceiling-mounted robot. 464/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 to 100 Nm - Socket wrench set - Collection receptacle - KUKA oil pump 0000-180-812 Oil drain hose 0000-158-094 Material The following material is required: Designation Article number Quantity Optigear Synt. ALR 150 (>>> 12.2 "Auxiliary and operating materials used" Page 636) Initial filling quantity: 8.30 l Refilling quantity CAUTION The quantity of oil drained depends on the draining time and the oil temperature. The refilling quantity is the quantity of oil that was drained from the gear unit at the correct operating temperature and with the correct draining time. This oil quantity must be determined. Only this quantity of oil may be used when refilling. If less than 70 % of the specified oil quantity flows out, flush the gear unit with the determined quantity of drained oil once, then pour in the amount of oil that was drained. If less than 50% of the specified oil quantity flows out (e.g. inclined installation), the flushing operation must be repeated twice. During the flushing procedure, move the axis at jog velocity throughout the entire axis range. The oil quantities specified in the table correspond to the oil quantities in the gear unit at first filling. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Preconditions • The gear unit is at operating temperature. • The oil filler hole (magnetic screw plug) in the rotating column is freely accessible; any covers must be removed beforehand. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 465/651 Maintenance KR QUANTEC-2 Work safety CAUTION High oil and surface temperatures after the robot has stopped operating If the oil change is carried out immediately after the robot has stopped operating, the oil temperature and the surface temperature are liable to be high. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to unintended robot motions Unintended robot motions may result in death, severe injuries and damage to property. • Secure the robot by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 8.3.1 Draining the gear oil from A1 Procedure 1. Place a suitable receptacle under the installed oil drain hose on the rotating column (>>> Fig. 8-4). 2. Unscrew the union nut from the installed oil drain hose on the rotating column. 3. Connect the oil drain hose to the quick coupling at interface A1 and press in for venting. Catch the oil as it drains out. 4. Measure the amount of oil drained and store or dispose of the used oil in accordance with the pertinent regulations. 466/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-4: Draining the gear oil from A1 1 Quick coupling 2 Oil drain hose 3 Rotating column 4 Oil drain hose, installed 5 Union nut 6 Collection receptacle 5. Disconnect the oil drain hose from the quick coupling at interface A1. 8.3.2 Filling gear unit A1 with gear oil 1. Connect the oil drain hose to the quick coupling and press in for venting. 2. Connect the oil pump to the oil drain hose on the rotating column. 3. Fill the specified amount of oil from below via the oil drain hose using the oil pump. 4. Disconnect the oil drain hose from the quick coupling. 5. Remove the oil pump from the drain hole. 6. Screw the union nut onto the installed oil drain hose on the rotating column and tighten; MA= 45 Nm, then check for leaks. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 467/651 Maintenance KR QUANTEC-2 Fig. 8-5: Filling gear unit A1 with gear oil 8.3.3 1 Quick coupling 2 Oil drain hose 3 Rotating column 4 Oil drain hose, installed 5 Oil pump 6 Union nut Concluding work The following concluding work must be carried out: • Remove oil residue. • Visual inspection, check for leaks. • Run the program in T1 mode and look out for irregularities. 8.4 Oil change in A2 Description The following sections describe the A2 gear oil change for floor-mounted robots. For ceiling-mounted robots, the procedure is to be applied analogously, but with the drain and filler holes reversed. Equipment The following equipment is required: 468/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 to 100 Nm - Socket wrench set - Collection receptacle - KUKA oil pump 0000-180-812 Maintenance KR QUANTEC-2 Material The following material is required: Designation Article number Quantity Optigear Synt. ALR 150 (>>> 12.2 "Auxiliary and operating materials used" Page 636) Initial filling quantity: 2.10 l Refilling quantity CAUTION The quantity of oil drained depends on the draining time and the oil temperature. The refilling quantity is the quantity of oil that was drained from the gear unit at the correct operating temperature and with the correct draining time. This oil quantity must be determined. Only this quantity of oil may be used when refilling. If less than 70 % of the specified oil quantity flows out, flush the gear unit with the determined quantity of drained oil once, then pour in the amount of oil that was drained. If less than 50% of the specified oil quantity flows out (e.g. inclined installation), the flushing operation must be repeated twice. During the flushing procedure, move the axis at jog velocity throughout the entire axis range. The oil quantities specified in the table correspond to the oil quantities in the gear unit at first filling. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot is in a position in which the oil filler hole and oil drain hole on the gear unit of axis 2 are accessible. • The gear unit is at operating temperature. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 469/651 Maintenance KR QUANTEC-2 Work safety CAUTION High oil and surface temperatures after the robot has stopped operating If the oil change is carried out immediately after the robot has stopped operating, the oil temperature and the surface temperature are liable to be high. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to unintended robot motions Unintended robot motions may result in death, severe injuries and damage to property. • Secure the robot by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 8.4.1 Draining the gear oil from A2 Procedure 1. Place a suitable receptacle under the rotating column (>>> Fig. 8-6). 2. Remove the oil drain hose from the rotating column and undo the union nut. 3. Remove the M18x1.5 magnetic screw plug for venting and catch the oil as it drains out. 4. Measure the amount of oil drained and store or dispose of the used oil in accordance with the pertinent regulations. 470/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-6: Draining the gear oil from A2 8.4.2 1 Magnetic screw plug M18x1.5 3 Union nut 2 Oil drain hose 4 Collection receptacle Filling A2 with gear oil Procedure 1. Connect the oil pump to the oil drain hose (>>> Fig. 8-7). 2. Pour in the specified amount of oil via the oil drain hose; the chamber fills from the bottom. 3. Clean the M18x1.5 magnetic screw plug and check the sealing element; exchange the magnetic screw plug if damaged. 4. Insert and tighten the magnetic screw plug; MA = 20 Nm. 5. Remove the oil pump. 6. Fit and tighten the union nut. 7. Check the magnetic screw plug and union nut for leaks. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 471/651 Maintenance KR QUANTEC-2 Fig. 8-7: Filling gear unit A2 with gear oil 8.4.3 1 Magnetic screw plug M18x1.5 3 Union nut 2 Oil drain hose 4 Oil pump Concluding work The following concluding work must be carried out: • Remove oil residue. • Visual inspection, check for leaks. • Run the program in T1 mode and look out for irregularities. 8.5 Oil change in A3 Description The following sections describe the A3 gear oil change for floor-mounted robots. For ceiling-mounted robots, the procedure is to be applied analogously, but with the drain and filler holes reversed. Equipment The following equipment is required: 472/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 to 100 Nm - Socket wrench set - Collection receptacle - KUKA oil pump 0000-180-812 Maintenance KR QUANTEC-2 Material The following material is required: Designation Article number Quantity Optigear Synt. ALR 150 (>>> 12.2 "Auxiliary and operating materials used" Page 636) Initial filling quantity: 1.40 l Refilling quantity CAUTION The quantity of oil drained depends on the draining time and the oil temperature. The refilling quantity is the quantity of oil that was drained from the gear unit at the correct operating temperature and with the correct draining time. This oil quantity must be determined. Only this quantity of oil may be used when refilling. If less than 70 % of the specified oil quantity flows out, flush the gear unit with the determined quantity of drained oil once, then pour in the amount of oil that was drained. If less than 50% of the specified oil quantity flows out (e.g. inclined installation), the flushing operation must be repeated twice. During the flushing procedure, move the axis at jog velocity throughout the entire axis range. The oil quantities specified in the table correspond to the oil quantities in the gear unit at first filling. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Preconditions • The robot is in a position in which the oil filler and drain holes on the axis 3 gear unit are accessible. • The gear unit is at operating temperature. • Axis 3 is in a horizontal position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 473/651 Maintenance KR QUANTEC-2 Work safety CAUTION High oil and surface temperatures after the robot has stopped operating If the oil change is carried out immediately after the robot has stopped operating, the oil temperature and the surface temperature are liable to be high. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to unintended robot motions Unintended robot motions may result in death, severe injuries and damage to property. • Secure the robot by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 8.5.1 Draining the gear oil from A3 Procedure 1. Place a suitable receptacle under the lower M16x1.5 magnetic screw plug and unscrew the M16x1.5 magnetic screw plug (>>> Fig. 8-8). It is easier to drain the oil if an M16x1.5 oil drain hose is screwed into the tapped hole of the magnetic screw plug. 2. Remove the upper M16x1.5 magnetic screw plug for venting and catch the oil as it drains out. 3. Measure the amount of oil drained and store or dispose of the used oil in accordance with the pertinent regulations. 474/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-8: Draining the gear oil from A3 8.5.2 1 Upper M16x1.5 magnetic screw plug 2 Oil drain hose 3 Collection receptacle 4 Lower M16x1.5 magnetic screw plug Filling gear unit A3 with gear oil Procedure 1. Connect the oil pump to the oil drain hose (>>> Fig. 8-9). 2. Pour in the specified amount of oil via the oil drain hose; the chamber fills from the bottom. 3. Clean both M16x1.5 magnetic screw plugs and check the sealing elements; exchange magnetic screw plugs if damaged. 4. Insert and tighten the upper M16x1.5 magnetic screw plug; MA = 20 Nm. 5. Remove oil drain hose and oil pump. 6. Insert and tighten the lower M16x1.5 magnetic screw plug; MA = 20 Nm. 7. Check both magnetic screw plugs for leaks. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 475/651 Maintenance KR QUANTEC-2 Fig. 8-9: Filling gear unit A3 with gear oil 8.5.3 1 Upper M16x1.5 magnetic screw plug 2 Oil drain hose 3 Oil pump 4 Lower M16x1.5 magnetic screw plug Concluding work The following concluding work must be carried out: • Remove oil residue. • Visual inspection, check for leaks. • Run the program in T1 mode and look out for irregularities. 8.6 Oil change in A4 Description The following sections describe the A4 gear oil change for floor-mounted robots. For ceiling-mounted robots, the procedure is to be applied analogously, but with the drain and filler holes reversed. Equipment The following equipment is required: 476/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 to 100 Nm - Socket wrench set - Collection receptacle - Funnel - Maintenance KR QUANTEC-2 Material The following material is required: Designation Article number Quantity Optigear Synt. ALR 150 (>>> 12.2 "Auxiliary and operating materials used" Page 636) Initial filling quantity: 2.10 l Refilling quantity CAUTION The quantity of oil drained depends on the draining time and the oil temperature. The refilling quantity is the quantity of oil that was drained from the gear unit at the correct operating temperature and with the correct draining time. This oil quantity must be determined. Only this quantity of oil may be used when refilling. If less than 70 % of the specified oil quantity flows out, flush the gear unit with the determined quantity of drained oil once, then pour in the amount of oil that was drained. If less than 50% of the specified oil quantity flows out (e.g. inclined installation), the flushing operation must be repeated twice. During the flushing procedure, move the axis at jog velocity throughout the entire axis range. The oil quantities specified in the table correspond to the oil quantities in the gear unit at first filling. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The gear unit is at operating temperature. • A3 is in a horizontal position. • Oil drain plugs on A4 are freely accessible. If necessary, remove inline wrist cover A4. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 477/651 Maintenance KR QUANTEC-2 Work safety CAUTION High oil and surface temperatures after the robot has stopped operating If the oil change is carried out immediately after the robot has stopped operating, the oil temperature and the surface temperature are liable to be high. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to unintended robot motions Unintended robot motions may result in death, severe injuries and damage to property. • Secure the robot by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 8.6.1 Draining the gear oil from A4 Procedure 1. Place a suitable receptacle under the lower magnetic screw plug and unscrew the M18x1.5 magnetic screw plug (>>> Fig. 8-10). It is easier to drain the oil if an M18x1.5 oil drain hose is screwed into the tapped hole of the magnetic screw plug. 2. Remove the upper M18x1.5 magnetic screw plug for venting and catch the oil as it drains out. 3. Measure the amount of oil drained and store or dispose of the used oil in accordance with the pertinent regulations. 478/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-10: Draining the gear oil from A4 8.6.2 1 Upper M18x1.5 magnetic screw plug 2 Oil drain hose 3 Collection receptacle 4 Lower M18x1.5 magnetic screw plug Filling gear unit A4 with gear oil Procedure 1. Clean both M18x1.5 magnetic screw plugs and check the sealing element; exchange magnetic screw plugs if damaged (>>> Fig. 8-11). 2. Insert and tighten the lower M18x1.5 magnetic screw plug; MA = 40 Nm. 3. Pour in, from above, the same amount of oil as was drained. 4. Insert and tighten the upper M18x1.5 magnetic screw plug; MA = 40 Nm. 5. Check both magnetic screw plugs for leaks. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 479/651 Maintenance KR QUANTEC-2 Fig. 8-11: Filling A4 with gear oil 1 Upper M18x1.5 magnetic screw plug 2 Funnel 3 Lower M18x1.5 magnetic screw plug 8.6.3 Concluding work The following concluding work must be carried out: • Remove oil residue. • Visual inspection, check for leaks. • Run the program in T1 mode and look out for irregularities. 8.7 Oil change in A5/A6 Description The following sections describe the A5/A6 gear oil change for floor-mounted robots. For ceiling-mounted robots, the procedure is to be applied analogously, but with the drain and filler holes reversed. Equipment The following equipment is required: 480/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Collection receptacle - Funnel - Maintenance KR QUANTEC-2 Material The following material is required: Designation Article number Quantity Optigear Synt. ALR 150 (>>> 12.2 "Auxiliary and operating materials used" Page 636) Initial filling quantity: 1.40 l for in-line wrist type ZH210 and ZH210 F 1.90 l for in-line wrist type ZH300 and ZH300 F Refilling quantity CAUTION The quantity of oil drained depends on the draining time and the oil temperature. The refilling quantity is the quantity of oil that was drained from the gear unit at the correct operating temperature and with the correct draining time. This oil quantity must be determined. Only this quantity of oil may be used when refilling. If less than 70 % of the specified oil quantity flows out, flush the gear unit with the determined quantity of drained oil once, then pour in the amount of oil that was drained. If less than 50% of the specified oil quantity flows out (e.g. inclined installation), the flushing operation must be repeated twice. During the flushing procedure, move the axis at jog velocity throughout the entire axis range. The oil quantities specified in the table correspond to the oil quantities in the gear unit at first filling. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 481/651 Maintenance KR QUANTEC-2 Precondition • The gear unit is at operating temperature. • Axis 3 is in a horizontal position. Work safety CAUTION High oil and surface temperatures after the robot has stopped operating If the oil change is carried out immediately after the robot has stopped operating, the oil temperature and the surface temperature are liable to be high. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to unintended robot motions Unintended robot motions may result in death, severe injuries and damage to property. • Secure the robot by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 8.7.1 Draining the gear oil on A5/A6 Procedure 1. Put the robot into operation, move axis 4 to the +90° position, and then secure the robot by activating the EMERGENCY STOP device (>>> 8.7.1 "Draining the gear oil on A5/A6" Page 482). 2. Place suitable receptacles under the magnetic screw plugs for A5 and A6 and unscrew the magnetic screw plugs. It is easier to drain the oil if an M18x1.5 oil drain hose is screwed into the tapped hole of the magnetic screw plug. NOTICE Overpressure Gear oil may escape. Keep the upper magnetic screw plug closed while draining oil. 482/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-12: Draining the gear oil from A5 and A6 1 Upper M18x1.5 magnetic screw plug 4 Collection receptacle 2 M18x1.5 magnetic screw plug for A6 5 M18x1.5 magnetic screw plug for A5 3 Oil drain hose (2x) 3. Put the robot into operation, move axis 4 to the 0° position, and then secure the robot by activating the EMERGENCY STOP device (>>> Fig. 8-13). 4. Place suitable receptacles under the lower magnetic screw plugs and unscrew the magnetic screw plugs. It is easier to drain the oil if an M18x1.5 oil drain hose is screwed into the tapped hole of the magnetic screw plug. 5. Measure the amount of oil drained and store or dispose of the used oil in accordance with the pertinent regulations. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 483/651 Maintenance KR QUANTEC-2 Fig. 8-13: Draining the gear oil from A5 and A6 1 Lower M18x1.5 magnetic screw plug 2 Oil drain hose 3 Collection receptacle 8.7.2 Filling gear unit A5/A6 with gear oil Procedure 1. Put the robot into operation, move axis 4 to the -90° position, and then secure the robot by activating the EMERGENCY STOP device (>>> Fig. 8-14). 2. Clean the 3 M18x1.5 magnetic screw plugs and check the sealing element; exchange the magnetic screw plugs if damaged. 3. Insert and tighten the lower M18x1.5 magnetic screw plug; MA = 20 Nm. 4. Fill approx. 1/3 of the quantity of oil drained into the opening on A5 from above. 5. Fill the remainder of the quantity of oil drained into the opening on A6 from above. 6. Insert and tighten the M18x1.5 magnetic screw plugs for A5 and A6; MA = 20 Nm. 7. Check the 3 magnetic screw plugs for leaks. 484/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-14: Filling gear units A5 and A6 with gear oil 8.7.3 1 M18x1.5 magnetic screw plug for A5 3 Funnel 2 M18x1.5 magnetic screw plug for A6 4 Lower M18x1.5 magnetic screw plug Concluding work The following concluding work must be carried out: • Remove oil residue. • Visual inspection, check for leaks. • Run the program in T1 mode and look out for irregularities. 8.8 Checking the counterbalancing system Description The following describes those tasks which must be carried out on the counterbalancing system at the intervals specified in the maintenance table. The gas pressure must always be checked on all diaphragm accumulators! Equipment The following equipment is required: Designation Article number Rag - Precondition • The robot is operational and can be moved at jog velocity. • There is no hazard posed by system components or other robots. • The robot is secured if work is being performed directly on the robot. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 485/651 Maintenance KR QUANTEC-2 Work safety WARNING Danger to life and limb due to unintended robot motions When carrying out the following work, the robot must be moved several times between the individual work steps. Unintentional movements of the robot can cause death, serious injury or material damage. • While work is being carried out on the robot, it must always be secured by actuating the EMERGENCY STOP device. • If work is carried out on an operational robot that is switched on, the robot must only be moved at reduced velocity. It must be possible to stop the robot at any time by actuating an EMERGENCY STOP device. Operation must be limited to what is absolutely necessary. • Warn all persons concerned before switching on and moving the robot. 8.8.1 Checking the counterbalancing system Procedure 1. Manually move A2 to -90° (link arm vertical). The robot arm may be in any position. 2. Wait 1 minute. 3. Secure the robot by pressing the EMERGENCY STOP device. 4. Check the following pressure on the pressure gauge: • Floor-mounted robot: 150 bar ±15 bar at 20 °C (293 K) ‒ KR 120 R2700-2 ‒ KR 120 R2700-2 ‒ KR 120 R3100-2 ‒ KR 120 R3100-2 ‒ KR 150 R2700-2 ‒ KR 150 R2700-2 ‒ KR 150 R3100-2 ‒ KR 150 R3100-2 ‒ KR 210 R2700-2 ‒ KR 210 R2700-2 • Floor-mounted robot: F F F F F 176 bar ±15 bar at 20 °C (293 K) ‒ KR 180 R2900-2 ‒ KR 180 R2900-2 F ‒ KR 210 R3100-2 ‒ KR 210 R3100-2 F ‒ KR 240 R2900-2 ‒ KR 240 R2900-2 F ‒ KR 250 R2700-2 ‒ KR 250 R2700-2 F ‒ KR 300 R2700-2 ‒ KR 300 R2700-2 F • Ceiling-mounted robot: 295 bar ±15 bar at 20 °C (293 K) ‒ KR 210 R3100-2 C ‒ KR 240 R2900-2 C ‒ KR 250 R2700-2 C 486/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 ‒ KR 300 R2700-2 C If the permissible value is not correct and/or there are deviations in the application, the value must be measured with a special pressure gauge and KUKA Service must be consulted. 5. Check the attachments for dirt and clean them if necessary. 6. Check the attachments for damage and ensure that they do not leak. In the case of leaks, identify the position of the leaks and remove oil residues. If necessary, exchange the counterbalancing system. 7. Check the collar for dirt and damage, clean it or have it exchanged by trained specialist personnel if necessary. 8.8.2 Concluding work The following concluding work must be carried out: • Remove oil residue. • Visual inspection, check for leaks. • Run the program in T1 mode and look out for irregularities. 8.9 Counterbalancing system, floor, exchanging Description The following sections describe the procedures for exchanging and filling the counterbalancing system of floor-mounted machines. The gas pressure must always be checked on both diaphragm accumulators! Equipment The following equipment is required: Designation Article number Torque wrench min. 20 Nm to 100 Nm - Socket set, ½ inch - Rope slings with sufficient load-bearing capacity - 2 cranes with sufficient load-bearing capacity - Pin extractor 0000-131-687 Clamping bush 0000-194-012 Pin locator 0000-190-253 Rag - Wooden pallet - Collection receptacle - Material The following material is required: MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 487/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 Designation Article number Quantity CBS assy, type GA20-A 0000-311-661 1 0000-311-666 1 0000-347-141 1 0000-347-140 1 For the following machines: • • • • • KR KR KR KR KR 120 120 150 150 210 R2700-2 R3100-2 R2700-2 R3100-2 R2700-2 CBS assy, type GA20 For the following machines: • • • • • KR KR KR KR KR 180 210 240 250 300 R2900-2 R3100-2 R2900-2 R2700-2 R2700-2 CBS assy type GA20-A-F For the following machines: • • • • • KR KR KR KR KR 120 120 150 150 210 R2700-2 R3100-2 R2700-2 R3100-2 R2700-2 F F F F F CBS assy type GA20-F For the following machines: • • • • • KR KR KR KR KR 180 210 240 250 300 R2900-2 R3100-2 R2900-2 R2700-2 R2700-2 F F F F F Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. 488/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Preconditions • • • • The robot is in the mechanical zero position. It must be possible to move the robot about axis 2. The robot must be correctly bolted to the floor. Any items of equipment that are likely to impede the removal and installation work have been removed. • The new counterbalancing system is correctly filled. Work safety WARNING Danger to life and limb due to unintended robot motions When carrying out the following work, the robot must be moved several times between the individual work steps. Unintentional movements of the robot can cause death, serious injury or material damage. • While work is being carried out on the robot, it must always be secured by actuating the EMERGENCY STOP device. • If work is carried out on an operational robot that is switched on, the robot must only be moved at reduced velocity. It must be possible to stop the robot at any time by actuating an EMERGENCY STOP device. Operation must be limited to what is absolutely necessary. • Warn all persons concerned before switching on and moving the robot. WARNING When removing or installing the counterbalancing system, care must be taken to avoid injury to arms, hands and fingers by crushing. Wear gloves and secure the counterbalancing system so that it cannot fall down or move unexpectedly. The counterbalancing system weighs approx. 40 kg. The counterbalancing system is pressurized. Particular caution must therefore be exercised and special knowledge put to effect when any work is performed on this system. Any improper handling constitutes a danger to life and limb. 8.9.1 Securing the link arm Procedure 1. Secure the link arm with a rope sling and attach the rope sling to the crane hook. 2. Raise the rope sling until it is taut. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 489/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 Fig. 8-15: Securing the link arm 8.9.2 Removing the counterbalancing system on a floor-mounted robot Procedure 1. Slacken the worm drive clip and push the bellows backwards (>>> Fig. 8-16). 2. Move the link arm in the plus direction until the clamping bush can be inserted between the cylinder and the articulated head. 3. Secure the robot by pressing the EMERGENCY STOP device. 4. Place clamping bush onto the free piston rod between the articulated head and the hydraulic cylinder and secure it with a screw. 5. Put the robot into operation and move the link arm carefully in the minus direction until the clamping bush is just clamped. CAUTION Material damage due to blocked counterbalancing system Do not move the counterbalancing system further in the minus direction. The counterbalancing system, link arm or rotating column may otherwise be damaged. ‒ Secure the robot by pressing the EMERGENCY STOP device. 490/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-16: Counterbalancing system, clamping bush 1 Clamping bush 2 Bellows with worm drive clip 3 Counterbalancing system 6. Secure the counterbalancing system with a rope sling and a crane and move the crane until the weight is supported by the rope sling (>>> Fig. 8-17). 7. Remove 4 M8x20-10.9 Allen screws and conical spring washers, and take off the retaining plate. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 491/651 Maintenance KR QUANTEC-2 Fig. 8-17: Counterbalancing system, pin 1 Spacer ring 5 Conical spring washer 2 Pin 6 Pin locator 3 Lock washer 7 Rope sling 4 M8x20-10.9 Allen screw (4x) 8 Thrust ring 8. Insert the pin locator on the right-hand side between the articulated head and the link arm. 9. Pull the pin out of the link arm using an M16 pin extractor. The pin is out of the precision fit area when it has been pulled out approx. 25 mm. 10. Put the robot into operation and move the link arm carefully in the plus direction until the articulated head is free. When moving the link arm, move the crane and rope sling at the same time, so that the weight of the arm is supported by the crane. 11. Secure the robot by pressing the EMERGENCY STOP device. 12. Swivel the counterbalancing system up and out of the link arm, moving the crane and rope sling at the same time. 13. Take off the pin locator, thrust ring and spacer ring that are now loose. CAUTION When forcing the counterbalancing system off the rotating column, an unfavorable position of the center of gravity may cause the counterbalancing system to move unexpectedly. To avoid injury and damage, the tension and position of the rope must be adjusted as necessary. 492/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 14. Remove 2 M12x30 Allen screws and lock washers, and take the cover off the rotating column (>>> Fig. 8-18). 15. Force the counterbalancing system off the pin in the rotating column. While forcing off the counterbalancing system, check the rope tension and if necessary correct it to prevent the components from being tilted. Fig. 8-18: Counterbalancing system, rotating column 1 Rope sling 3 Conical spring washer 2 Cover 4 M12x30-10.9 Allen screw (2x) 16. Continue raising the counterbalancing system with the crane and set it down on a suitable support. 17. If the counterbalancing system is not to be reinstalled, it must be protected against corrosion before being put into storage. If a new counterbalancing system is not being installed immediately, the robot can be moved into a safe position and the rope securing the link arm can be removed. The robot may only be moved again in order to install the new counterbalancing system. 8.9.3 Installing the counterbalancing system Description The (>>> Fig. 8-21) clamping bush is only required for the counterbalancing system for floor-mounted robots. Procedure 1. Remove corrosion protection from the counterbalancing system and check that no part of it is missing. 2. If necessary, put the robot into operation and move the link arm into approximately the -85° position. 3. Secure the robot by pressing the EMERGENCY STOP device. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 493/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 4. Lift the counterbalancing system with a rope sling and bring it to the site of installation (>>> Fig. 8-19). 5. Mount the counterbalancing system sideways on the pin in the rotating column, and align. 6. If necessary, adjust the rope tension. 7. Mount cover. 8. Apply Drei Bond 1342 adhesive to 2 M12x30-10.9 Allen screws and insert them into the cover with conical spring washers. 9. Tighten 2 M12x30-10.9 Allen screws with a torque wrench. Increase the tightening torque to the specified value in several stages. Fig. 8-19: Counterbalancing system, rotating column 1 Rope sling 3 Conical spring washer 2 Cover 4 M12x30-10.9 Allen screw (2x) 10. Put the robot into operation. 11. Move the link arm until the counterbalancing system can be inserted into the link arm. At the same time, move the element securing the link arm accordingly (>>> Fig. 8-20). 12. Lower the counterbalancing system. 13. Apply a thin but continuous coat of Microlube GL 261 to the thrust ring and spacer ring. Insert the articulated head with the thrust ring and spacer ring into the link arm, and align. Observe installation position of thrust ring and spacer ring! 14. Move the link arm and counterbalancing system until the holes are aligned. 15. Insert the pin with the aid of the device. 16. Mount the retaining plate and insert 4 M8x20-10.9 Allen screws and conical spring washers. 17. Tighten 4 M8x20-10.9 Allen screws with a torque wrench. Increase the tightening torque to the specified value in several stages. 18. Remove the rope sling on the counterbalancing system. 494/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-20: Counterbalancing system, pin 1 Spacer ring 5 Conical spring washer 2 Pin 6 Pin locator 3 Lock washer 7 Rope sling 4 M8x20-10.9 Allen screw (4x) 8 Thrust ring 19. Put the robot into operation. 20. Move the link arm in the plus direction until the clamping bush between the cylinder and the articulated head is released, slacken the setscrew and remove the clamping bush (>>> Fig. 8-21). CAUTION Material damage due to blocked counterbalancing system Do not move the counterbalancing system further in the minus direction. The counterbalancing system, link arm or rotating column may otherwise be damaged. ‒ Secure the robot by pressing the EMERGENCY STOP device. 21. Mount the bellows on the cylinder and the articulated head and fasten with worm drive clips. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 495/651 Maintenance KR QUANTEC-2 Fig. 8-21: Counterbalancing system, clamping bush 1 Clamping bush 2 Bellows with worm drive clip 3 Counterbalancing system 22. Check the pressure on the counterbalancing system (>>> 8.8 "Checking the counterbalancing system" Page 485). 8.9.4 Removing the equipment securing the link arm Procedure 1. Slacken the rope sling and detach from the crane. 2. Remove the rope sling from the robot. Fig. 8-22: Securing the link arm 496/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 8.9.5 Checking the counterbalancing system Procedure 1. Manually move A2 to -90° (link arm vertical). The robot arm may be in any position. 2. Wait 1 minute. 3. Secure the robot by pressing the EMERGENCY STOP device. 4. Check the following pressure on the pressure gauge: • Floor-mounted robot: 150 bar ±15 bar at 20 °C (293 K) ‒ KR 120 R2700-2 ‒ KR 120 R2700-2 ‒ KR 120 R3100-2 ‒ KR 120 R3100-2 ‒ KR 150 R2700-2 ‒ KR 150 R2700-2 ‒ KR 150 R3100-2 ‒ KR 150 R3100-2 ‒ KR 210 R2700-2 ‒ KR 210 R2700-2 • Floor-mounted robot: F F F F F 176 bar ±15 bar at 20 °C (293 K) ‒ KR 180 R2900-2 ‒ KR 180 R2900-2 F ‒ KR 210 R3100-2 ‒ KR 210 R3100-2 F ‒ KR 240 R2900-2 ‒ KR 240 R2900-2 F ‒ KR 250 R2700-2 ‒ KR 250 R2700-2 F ‒ KR 300 R2700-2 ‒ KR 300 R2700-2 F • Ceiling-mounted robot: 295 bar ±15 bar at 20 °C (293 K) ‒ ‒ ‒ ‒ KR KR KR KR 210 240 250 300 R3100-2 R2900-2 R2700-2 R2700-2 C C C C If the permissible value is not correct and/or there are deviations in the application, the value must be measured with a special pressure gauge and KUKA Service must be consulted. 5. Check the attachments for dirt and clean them if necessary. 6. Check the attachments for damage and ensure that they do not leak. In the case of leaks, identify the position of the leaks and remove oil residues. If necessary, exchange the counterbalancing system. 7. Check the collar for dirt and damage, clean it or have it exchanged by trained specialist personnel if necessary. 8.9.6 Concluding work The following concluding work must be carried out: • Move link arm and carry out a function test. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 497/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 • Check the pressure on the counterbalancing system pressure gauge in the neutral position (piston rod is retracted to the maximum extent) against the pressure table. • Move the link arm against the positive and negative software limit stops, observing the counterbalancing system pressure gauge. The counterbalancing system pressure must rise constantly from the neutral position in both the plus and minus directions. • Visual inspection, check for leaks. 8.10 Exchanging the counterbalancing system on a ceiling-mounted robot Description The following sections describe the procedures for exchanging and filling the counterbalancing system of ceiling-mounted machines. To remove and install the counterbalancing system, the ceiling-mounted robot must be removed from the ceiling and securely fastened to the floor (to the foundation). The gas pressure must always be checked on both diaphragm accumulators! Equipment The following equipment is required: Designation Article number Torque wrench min. 20 Nm to 100 Nm - Socket set, ½ inch - Rope slings with sufficient load-bearing capacity - 2 cranes with sufficient load-bearing capacity - Pin extractor 0000-131-687 Pin locator 0000-190-253 Rag - Wooden pallet - Collection receptacle - Material The following material is required: Designation Article number Quantity Ceiling CBS assy type GA21 0000-345-476 1 For the following machines: • • • • 498/651 | www.kuka.com KR KR KR KR 210 240 250 300 R3100-2 R2900-2 R2700-2 R2700-2 C C C C MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Preconditions • • • • The robot is in the mechanical zero position. It must be possible to move the robot about axis 2. The robot must be correctly bolted to the floor. Any items of equipment that are likely to impede the removal and installation work have been removed. • The new counterbalancing system is correctly filled. Work safety WARNING Danger to life and limb due to unintended robot motions When carrying out the following work, the robot must be moved several times between the individual work steps. Unintentional movements of the robot can cause death, serious injury or material damage. • While work is being carried out on the robot, it must always be secured by actuating the EMERGENCY STOP device. • If work is carried out on an operational robot that is switched on, the robot must only be moved at reduced velocity. It must be possible to stop the robot at any time by actuating an EMERGENCY STOP device. Operation must be limited to what is absolutely necessary. • Warn all persons concerned before switching on and moving the robot. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 499/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 WARNING When removing or installing the counterbalancing system, care must be taken to avoid injury to arms, hands and fingers by crushing. Wear gloves and secure the counterbalancing system so that it cannot fall down or move unexpectedly. The counterbalancing system weighs approx. 40 kg. The counterbalancing system is pressurized. Particular caution must therefore be exercised and special knowledge put to effect when any work is performed on this system. Any improper handling constitutes a danger to life and limb. 8.10.1 Securing the link arm Procedure 1. Secure the link arm with a rope sling and attach the rope sling to the crane hook. 2. Raise the rope sling until it is taut. Fig. 8-23: Securing the link arm 8.10.2 Removing the counterbalancing system on a ceiling-mounted robot Procedure 1. Remove the screw cap and connect the hose to the vent valve. 2. Place a suitable receptacle under the hose and collect the hydraulic oil. 500/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-24: Counterbalancing system, draining hydraulic oil 1 Screw cap and vent valve 2 Pressure gauge 3 Hose 4 Collection receptacle 3. Drain the oil until the pressure gauge reads zero. The oil side of the diaphragm accumulator is now depressurized. Leave hose connected to the vent valve and leave the vent valve open. 4. Secure the counterbalancing system with a rope sling and a crane and move the crane until the weight is supported by the rope sling (>>> Fig. 8-25). 5. Remove 4 M8x20-10.9 Allen screws and conical spring washers, and take off the lock washer. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 501/651 Maintenance KR QUANTEC-2 Fig. 8-25: Counterbalancing system, pin 1 Spacer ring 5 Conical spring washer 2 Pin 6 Pin locator 3 Lock washer 7 Rope sling 4 M8x20-10.9 Allen screw (4x) 8 Thrust ring 6. Insert the pin locator on the right-hand side between the articulated head and the link arm. 7. Pull the pin out of the link arm using an M16 pin extractor. The pin is out of the precision fit area when it has been pulled out approx. 25 mm. 8. Put the robot into operation and move the link arm carefully in the plus direction until the articulated head is free. When moving the link arm, move the crane and rope sling at the same time, so that the weight of the arm is supported by the crane. 9. Secure the robot by pressing the EMERGENCY STOP device. 10. Swivel the counterbalancing system up and out of the link arm, moving the crane and rope sling at the same time. 11. Take off the pin locator, thrust ring and spacer ring that are now loose. CAUTION When forcing the counterbalancing system off the rotating column, an unfavorable position of the center of gravity may cause the counterbalancing system to move unexpectedly. To avoid injury and damage, the tension and position of the rope must be adjusted as necessary. 502/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 12. Remove 2 M12x30 Allen screws and lock washers, and take the cover off the rotating column (>>> Fig. 8-26). 13. Force the counterbalancing system off the pin in the rotating column. While forcing off the counterbalancing system, check the rope tension and if necessary correct it to prevent the components from being tilted. Fig. 8-26: Counterbalancing system, rotating column 1 Rope sling 3 Conical spring washer 2 Cover 4 M12x30-10.9 Allen screw (2x) 14. Continue raising the counterbalancing system with the crane and set it down on a suitable support. 15. If the counterbalancing system is not to be reinstalled, it must be protected against corrosion before being put into storage. If a new counterbalancing system is not being installed immediately, the robot can be moved into a safe position and the rope securing the link arm can be removed. The robot may only be moved again in order to install the new counterbalancing system. 8.10.3 Installing the counterbalancing system on a ceiling-mounted robot Procedure 1. Remove corrosion protection from the counterbalancing system and check that no part of it is missing. 2. If necessary, put the robot into operation and move the link arm into approximately the -85° position. 3. Secure the robot by pressing the EMERGENCY STOP device. 4. Lift the counterbalancing system with a rope sling and bring it to the site of installation (>>> Fig. 8-27). 5. Mount the counterbalancing system sideways on the pin in the rotating column, and align. 6. If necessary, adjust the rope tension. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 503/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 7. Mount cover. 8. Apply Drei Bond 1342 adhesive to 2 M12x30-10.9 Allen screws and insert them into the cover with conical spring washers. 9. Tighten 2 M12x30-10.9 Allen screws with a torque wrench. Increase the tightening torque to the specified value in several stages. Fig. 8-27: Counterbalancing system, rotating column 1 Rope sling 3 Conical spring washer 2 Cover 4 M12x30-10.9 Allen screw (2x) 10. Put the robot into operation. 11. Move the link arm until the counterbalancing system can be inserted into the link arm. At the same time, move the element securing the link arm accordingly (>>> Fig. 8-28). 12. Lower the counterbalancing system. 13. Apply a thin but continuous coat of Microlube GL 261 to the thrust ring and spacer ring. Insert the articulated head with the thrust ring and spacer ring into the link arm, and align. Observe installation position of thrust ring and spacer ring! 14. Move the link arm and counterbalancing system until the holes are aligned. 15. Insert the pin with the aid of the device. 16. Mount the retaining plate and insert 4 M8x20-10.9 Allen screws and conical spring washers. 17. Tighten 4 M8x20-10.9 Allen screws with a torque wrench. Increase the tightening torque to the specified value in several stages. 18. Remove the rope sling on the counterbalancing system. 504/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Maintenance KR QUANTEC-2 Fig. 8-28: Counterbalancing system, pin 1 Spacer ring 5 Conical spring washer 2 Pin 6 Pin locator 3 Lock washer 7 Rope sling 4 M8x20-10.9 Allen screw (4x) 8 Thrust ring 19. Mount the bellows on the cylinder and the articulated head and fasten with worm drive clips. 20. Check the pressure on the counterbalancing system (>>> 8.8 "Checking the counterbalancing system" Page 485). 8.10.4 Removing the equipment securing the link arm Procedure 1. Slacken the rope sling and detach from the crane. 2. Remove the rope sling from the robot. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 505/651 Maintenance KR QUANTEC-2 Fig. 8-29: Securing the link arm 8.10.5 Checking the counterbalancing system Procedure 1. Manually move A2 to -90° (link arm vertical). The robot arm may be in any position. 2. Wait 1 minute. 3. Secure the robot by pressing the EMERGENCY STOP device. 4. Check the following pressure on the pressure gauge: • Floor-mounted robot: 150 bar ±15 bar at 20 °C (293 K) ‒ KR 120 R2700-2 ‒ KR 120 R2700-2 ‒ KR 120 R3100-2 ‒ KR 120 R3100-2 ‒ KR 150 R2700-2 ‒ KR 150 R2700-2 ‒ KR 150 R3100-2 ‒ KR 150 R3100-2 ‒ KR 210 R2700-2 ‒ KR 210 R2700-2 • Floor-mounted robot: ‒ ‒ ‒ ‒ ‒ ‒ ‒ ‒ ‒ 506/651 | www.kuka.com KR KR KR KR KR KR KR KR KR 180 180 210 210 240 240 250 250 300 R2900-2 R2900-2 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 F F F F F 176 bar ±15 bar at 20 °C (293 K) F F F F MA KR QUANTEC-2 V11 | Issued: 21.08.2023 ‒ KR 300 R2700-2 F • Ceiling-mounted robot: 295 bar ±15 bar at 20 °C (293 K) ‒ ‒ ‒ ‒ KR KR KR KR 210 240 250 300 R3100-2 R2900-2 R2700-2 R2700-2 C C C C If the permissible value is not correct and/or there are deviations in the application, the value must be measured with a special pressure gauge and KUKA Service must be consulted. 5. Check the attachments for dirt and clean them if necessary. 6. Check the attachments for damage and ensure that they do not leak. In the case of leaks, identify the position of the leaks and remove oil residues. If necessary, exchange the counterbalancing system. 7. Check the collar for dirt and damage, clean it or have it exchanged by trained specialist personnel if necessary. 8.10.6 Concluding work The following concluding work must be carried out: • Move link arm and carry out a function test. • Check the pressure on the counterbalancing system pressure gauge in the neutral position (piston rod is retracted to the maximum extent) against the pressure table. • Move the link arm against the positive and negative software limit stops, observing the counterbalancing system pressure gauge. The counterbalancing system pressure must rise constantly from the neutral position in both the plus and minus directions. • Visual inspection, check for leaks. 8.11 Cleaning the robot Description The robot must be cleaned in compliance with the instructions given here in order to prevent damage. These instructions only refer to the robot. Equipment The following equipment is required: Designation Article number Permissible cleaning tools (e.g. cloths, brushes) - Material The following material is required: Designation Article number Quantity Cleaning agent solvent-free, water-soluble, non-flammable, non-aggressive, no steam, no refrigerants - - MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 507/651 Maintenance KR QUANTEC-2 Maintenance KR QUANTEC-2 Precondition • The robot controller is switched off. • The robot is freely accessible. Work safety NOTICE The following must be taken into consideration when carrying out cleaning work (material damage may otherwise result): • Cleaning must be in accordance with the corresponding cleaning instructions. • Do not use high-pressure cleaners. • Compressed air must not be used to clean bearing and sealing points. • It must be ensured that no cleaning agent enters electrical or mechanical system components. 8.11.1 Cleaning Procedure 1. Shut down the robot. 2. If necessary, shut adjacent system components down and lock them. 3. Remove enclosures if this is necessary in order to carry out the cleaning work. 4. Clean the robot. 5. Fully remove all cleaning agents from the robot. 6. Clean any areas of corrosion and reapply corrosion protection. 7. Install any safety equipment that has been removed. 8. Put back in place any enclosures that have been removed. 8.11.2 Concluding work The following concluding work must be carried out: • Remove cleaning agents and equipment from the workspace of the robot. • Dispose of cleaning agents in accordance with the pertinent regulations. • Replace any damaged or illegible plates and covers. • Install any safety equipment that has been removed and check that it is functioning correctly. Only a functional system with all safety functions may be put back into operation. 508/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 9 Repair KR QUANTEC-2 Repair Only maintenance and repair work described in this document may be performed. Work that exceeds this scope may only be carried out by personnel specially trained by KUKA. Information about KUKA College and its training program can be found at college.kuka.com or can be obtained directly from our subsidiaries. In the case of support and repair services provided by KUKA, KUKA Service must be informed in advance about potential contamination or hazards. Non-compliance nullifies warranty and liability claims. 9.1 Exchanging motor A1 Description The following instructions describe the exchange of the motor. This description applies to floor-mounted robots. If the robot is installed in an inclined or suspended position, the procedure is to be applied analogously. During removal of the motor, the robot can independently move about this axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end position (e.g. buffer) can be used to secure against motions. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Brush - SEMD/MEMD mastering kit 0000-228-936 Material The following material is required: MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 509/651 Repair KR QUANTEC-2 Designation Article number Quantity SPP motor 3.8kW L0 ME 0000-334-486 1 0000-334-485 1 0000-362-290 1 0000-362-288 1 For the following machines: • • • • • • KR KR KR KR KR KR 120 120 150 150 180 210 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 SPP motor 5.5kW L0 ME For the following machines: • • • • • • • • KR KR KR KR KR KR KR KR 210 210 240 240 250 250 300 300 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 C C C C SPP motor 3.8kW L0 ME For the following machines: • • • • • • KR KR KR KR KR KR 120 120 150 150 180 210 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 F F F F F F SPP motor 5.5kW L0 ME For the following machines: • • • • KR KR KR KR 210 240 250 300 R3100-2 R2900-2 R2700-2 R2700-2 F F F F Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. 510/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot is secured by means of an EMERGENCY STOP device. It must be ensured that the robot cannot be switched on by unauthorized persons. Work safety CAUTION Risk of burns on hot surfaces The surfaces of the motors are often hot immediately after the robot has been decommissioned. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to live components Components may remain energized after the robot system has been switched off. Death, severe injuries or damage to property may result. • Switch off the robot system at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the robot controller and power cable are deenergized. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.1.1 Removing motor A1 Procedure 1. Release and unplug connectors XM1 and XP1 at the sockets. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 511/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 2. Unscrew 4 M12x25-8.8-A2K Allen screws. 3. Release and lift out motor A1, being careful not to tilt it. 4. Cover the input shaft and protect it against fouling. Fig. 9-1: Motor A1 1 M12x25-8.8-A2K Allen screw 2 Motor A1 3 Connector XM1 4 Connector XP1 5. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.1.2 Preparing a new motor for installation Procedure 1. Clean the involute toothing of motor and gear unit before installation and apply a thin but continuous coat of Microlube GL 261 grease. 2. Clean the mounting surface for the motor. 3. Check the condition of the O-ring on the motor shaft. In the case of damage and/or wear, the O-ring must be exchanged. 512/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-2: Preparing a new motor A1-A3 for installation 1 Motor 2 O-ring 3 Involute toothing 9.1.3 Installing motor A1 Procedure 1. Position sockets XM1 and XP1 as shown. 2. Insert motor A1, taking care not to tilt it. Insertion of motor can be facilitated by turning it gently about its rotational axis. 3. Insert 4 M12x25-8.8-A2K Allen screws. 4. Tighten 4 M12x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 5. Plug connectors XM1 and XP1 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 513/651 Repair KR QUANTEC-2 Fig. 9-3: Motor A1 1 M12x25-8.8-A2K Allen screw 2 Motor A1 3 Connector XM1 4 Connector XP1 9.1.4 Concluding work The following concluding work must be carried out: • Move A1 of the robot and look out for irregularities. • Carry out mastering of A1. Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity (T1) mode. 9.2 Exchanging motor A2 Description The following instructions describe the exchange of the motor. This description applies to floor-mounted robots. If the robot is installed in an inclined or suspended position, the procedure is to be applied analogously. 514/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 During removal of the motor, the robot can independently move about this axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end position (e.g. buffer) can be used to secure against motions. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Crane with sufficient load-bearing capacity - Rope sling with sufficient load-bearing capacity - Brush - SEMD/MEMD mastering kit 0000-228-936 Material The following material is required: Designation Article number Quantity SPP motor 5.5kW L0 ME 0000-334-485 1 0000-334-484 1 For the following machines: • • • • • • KR KR KR KR KR KR 120 120 150 150 180 210 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 SPP motor 5.8kW L0 ME For the following machines: • • • • • • • • KR KR KR KR KR KR KR KR 210 210 240 240 250 250 300 300 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 C C C C www.kuka.com | 515/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 Designation Article number Quantity SPP motor 5.5kW L0 ME 0000-362-288 1 0000-362-289 1 For the following machines: • • • • • • KR KR KR KR KR KR 120 120 150 150 180 210 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 F F F F F F SPP motor 5.8kW L0 ME For the following machines: • • • • KR KR KR KR 210 240 250 300 R3100-2 R2900-2 R2700-2 R2700-2 F F F F Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot is secured by means of an EMERGENCY STOP device. It must be ensured that the robot cannot be switched on by unauthorized persons. • The removal site is freely accessible for work tasks involving a crane. 516/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Work safety DANGER Danger to life and limb due to defective or unsuitable load suspension devices If defective or non-approved load suspension devices are used, the load may fall off or start to swing. Failure to observe this can lead to death, injury or property damage. • Before using load suspension devices, check for defects (e.g. damage, corrosion, deformation, wear, cracks) and exchange components if necessary. • Use only inspected and approved load suspension devices. • Use only load suspension devices with a sufficient load-bearing capacity. CAUTION Risk of burns on hot surfaces The surfaces of the motors are often hot immediately after the robot has been decommissioned. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to live components Components may remain energized after the robot system has been switched off. Death, severe injuries or damage to property may result. • Switch off the robot system at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the robot controller and power cable are deenergized. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.2.1 Securing the link arm Procedure 1. Secure the link arm with a rope sling and attach the rope sling to the crane hook. 2. Raise the rope sling until it is taut. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 517/651 Repair KR QUANTEC-2 Fig. 9-4: Securing the link arm 9.2.2 Removing motor A2 Procedure 1. Release and unplug connectors XM2 and XP2 at the sockets. 2. Place the rope sling around motor A2 and raise it using the crane until the weight of motor A2 is supported by the rope sling. 3. Unscrew 4 M12x25-8.8-A2K Allen screws. 4. Release and carefully lift out motor A2, taking care not to tilt it. 518/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-5: Motor A2 1 Motor A2 2 Rope sling 3 Connector XM2 4 Connector XP2 5 M12x25-8.8-A2K Allen screw 5. Cover the aperture on motor mount A2 and protect it against fouling. 6. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.2.3 Preparing a new motor for installation Procedure 1. Clean the involute toothing of motor and gear unit before installation and apply a thin but continuous coat of Microlube GL 261 grease. 2. Clean the mounting surface for the motor. 3. Check the condition of the O-ring on the motor shaft. In the case of damage and/or wear, the O-ring must be exchanged. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 519/651 Repair KR QUANTEC-2 Fig. 9-6: Preparing a new motor A1-A3 for installation 1 Motor 2 O-ring 3 Involute toothing 9.2.4 Installing motor A2 Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the involute toothing of motor A2 and gear unit A2 before installation and apply a thin but continuous coat of Microlube GL 261 grease. 3. Clean the mounting surface of motor A2 on the motor mount. 4. Check the condition of the O-ring on the motor shaft; exchange if necessary. 5. Position sockets XM2 and XP2 as shown. 6. With the rope sling, pick up and insert motor A2, being careful not to tilt it. Insertion of motor can be facilitated by turning it gently about its rotational axis. 7. Insert 4 M12x25-8.8-A2K Allen screws. 8. Tighten 4 M12x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 9. Plug connectors XM2 and XP2 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). 520/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-7: Motor A2 1 Motor A2 2 Rope sling 3 Connector XM2 4 Connector XP2 5 M12x25-8.8-A2K Allen screw 9.2.5 Removing the equipment securing the link arm Procedure 1. Slacken the rope sling and detach from the crane. 2. Remove the rope sling from the robot. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 521/651 Repair KR QUANTEC-2 Fig. 9-8: Securing the link arm 9.2.6 Concluding work The following concluding work must be carried out: • Move A2 of the robot and look out for irregularities. • Carry out mastering of A2. Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity (T1) mode. 9.3 Exchanging motor A3 Description The following instructions describe the exchange of the motor. This description applies to floor-mounted robots. If the robot is installed in an inclined or suspended position, the procedure is to be applied analogously. During removal of the motor, the robot can independently move about this axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end position (e.g. buffer) can be used to secure against motions. Equipment The following equipment is required: 522/651 | www.kuka.com Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Designation Article number Crane with sufficient load-bearing capacity - Rope sling with sufficient load-bearing capacity - Brush - SEMD/MEMD mastering kit 0000-228-936 Repair KR QUANTEC-2 Material The following material is required: Designation Article number Quantity SPP motor 3.8kW L0 ME 0000-334-486 1 0000-334-485 1 0000-334-484 1 0000-362-290 1 0000-362-288 1 For the following machines: • KR 120 R2700-2 SPP motor 5.5kW L0 ME For the following machines: • • • • • KR KR KR KR KR 120 150 150 180 210 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 SPP motor 5.8kW L0 ME For the following machines: • • • • • • • • KR KR KR KR KR KR KR KR 210 210 240 240 250 250 300 300 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 C C C C SPP motor 3.8kW L0 ME For the following machines: • KR 120 R2700-2 F SPP motor 5.5kW L0 ME For the following machines: • • • • • KR KR KR KR KR 120 150 150 180 210 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 F F F F F www.kuka.com | 523/651 Repair KR QUANTEC-2 Designation Article number Quantity SPP motor 5.8kW L0 ME 0000-362-289 1 For the following machines: • • • • KR KR KR KR 210 240 250 300 R3100-2 R2900-2 R2700-2 R2700-2 F F F F Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot is secured by means of an EMERGENCY STOP device. It must be ensured that the robot cannot be switched on by unauthorized persons. • The removal site is freely accessible for work tasks involving a crane. Work safety DANGER Danger to life and limb due to defective or unsuitable load suspension devices If defective or non-approved load suspension devices are used, the load may fall off or start to swing. Failure to observe this can lead to death, injury or property damage. • Before using load suspension devices, check for defects (e.g. damage, corrosion, deformation, wear, cracks) and exchange components if necessary. • Use only inspected and approved load suspension devices. • Use only load suspension devices with a sufficient load-bearing capacity. 524/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 CAUTION Risk of burns on hot surfaces The surfaces of the motors are often hot immediately after the robot has been decommissioned. Touching them may result in burns. • Wear protective gloves. WARNING Danger to life and limb due to live components Components may remain energized after the robot system has been switched off. Death, severe injuries or damage to property may result. • Switch off the robot system at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the robot controller and power cable are deenergized. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.3.1 Securing the robot arm Procedure 1. Secure the robot arm with a rope sling and attach the rope sling to the crane hook. 2. Move the crane upwards until the rope sling is taut. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 525/651 Repair KR QUANTEC-2 Fig. 9-9: Securing robot arm 9.3.2 Removing motor A3 Procedure 1. Release and unplug connectors XM3 and XP3 at the sockets. 2. Place the rope sling around motor A3 and raise it using the crane until the weight of motor A3 is supported by the rope sling. 3. Unscrew 4 M12x25-8.8-A2K Allen screws. 4. Release and carefully lift out motor A3, taking care not to tilt it. 526/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-10: Motor A3 1 Connector XM3 2 Connector XP3 3 Motor A3 4 M12x25-8.8-A2K Allen screw 5 Rope sling 5. Remove protective tube A3 (not required with the upgrade). MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 527/651 Repair KR QUANTEC-2 Fig. 9-11: Protective tube A3 1 Robot arm 2 Protective tube A3 3 Link arm 6. Cover the aperture on motor mount A3 and protect it against fouling. 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.3.3 Preparing a new motor for installation Procedure 1. Clean the involute toothing of motor and gear unit before installation and apply a thin but continuous coat of Microlube GL 261 grease. 2. Clean the mounting surface for the motor. 3. Check the condition of the O-ring on the motor shaft. In the case of damage and/or wear, the O-ring must be exchanged. 528/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-12: Preparing a new motor A1-A3 for installation 1 Motor 2 O-ring 3 Involute toothing 9.3.4 Installing motor A3 Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing of motor A3 and gear unit A3 before installation and apply a thin but continuous coat of Microlube GL 261 grease. 3. Clean the mounting surface of motor A3 on gear unit A3. 4. Check the condition of the O-ring on the motor shaft; exchange if necessary. 5. Insert protective tube A3 (not removed with the upgrade). MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 529/651 Repair KR QUANTEC-2 Fig. 9-13: Protective tube A3 1 Robot arm 2 Protective tube A3 3 Link arm 6. With the rope sling, pick up and insert motor A3, being careful not to tilt it. Insertion of motor can be facilitated by turning it gently about its rotational axis. 7. Insert 4 M12x25-8.8-A2K Allen screws. 8. Tighten 4 M12x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 9. Position sockets XM3 and XP3 as shown. 10. Plug connectors XM3 and XP3 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). 530/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-14: Motor A3 1 Connector XM3 2 Connector XP3 3 Motor A3 4 M12x25-8.8-A2K Allen screw 5 Rope sling 9.3.5 Removing the equipment securing the robot arm Procedure 1. Slacken the rope sling and detach from the crane. 2. Remove the rope sling from the robot arm. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 531/651 Repair KR QUANTEC-2 Fig. 9-15: Securing robot arm 9.3.6 Concluding work The following concluding work must be carried out: • Move A3 of the robot and look out for irregularities. • Carry out mastering of A3. Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity mode (T1). 9.4 Exchanging motor A4 Description The following instructions describe the exchange of the motor. This description applies to floor-mounted robots. If the robot is installed in an inclined or suspended position, the procedure is to be applied analogously. During removal of the motor, the robot can independently move about this axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end position (e.g. buffer) can be used to secure against motions. Equipment The following equipment is required: 532/651 | www.kuka.com Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Brush - MA KR QUANTEC-2 V11 | Issued: 21.08.2023 SEMD/MEMD mastering kit Repair KR QUANTEC-2 0000-228-936 Material The following material is required: Designation Article number Quantity SPP motor 1.7kW L0 ME 0000-336-054 1 0000-334-482 1 0000-362-271 1 0000-362-287 1 For the following machines: • • • • • KR KR KR KR KR 120 120 150 150 180 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 SPP motor 2.5kW L0 ME For the following machines: • • • • • • • • • KR KR KR KR KR KR KR KR KR 210 210 210 240 240 250 250 300 300 R2700-2 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 C C C C SPP motor 1.7kW L0 ME For the following machines: • • • • • KR KR KR KR KR 120 120 150 150 180 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 F F F F F SPP motor 2.5kW L0 ME For the following machines: • • • • • KR KR KR KR KR 210 210 240 250 300 R2700-2 R3100-2 R2900-2 R2700-2 R2700-2 F F F F F Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 533/651 Repair KR QUANTEC-2 • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot must be prevented from tipping. If necessary, fasten the robot to the mounting base. • The robot is secured against axis motions. • There is no hazard posed by system components. • Tools have been removed. Work safety WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cause burns. • Avoid contact. • Take appropriate safety precautions, e.g. wear protective gloves. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. 534/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.4.1 Removing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM4 and XP4 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A4. 3. Release motor A4 and pull it out together with connecting shaft A4, being careful not to tilt it. 4. Set down motor A4 together with connecting shaft A4. Fig. 9-16: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 535/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 5. Pull connecting shaft A4 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. Fig. 9-17: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.4.2 Preparing the new motor A4 - A5 for installation Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Clean the involute toothing of motor and connecting shaft before installation and apply a thin but continuous coat of Microlube GL 261 grease. 2. Clean the mounting surface for the motor. 3. Check the condition of the compression spring and, if applicable, backup ring on the motor shaft. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. In the case of damage and/or wear, the compression spring must be exchanged. 536/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-18: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 9.4.3 Installing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A4 and motor shaft A4, and check for wear. In the case of damage and/or wear, connecting shaft A4 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A4. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A4 onto motor shaft A4. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 537/651 Repair KR QUANTEC-2 Fig. 9-19: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 6. The mounting surfaces (motor A4 and robot arm) must be dry and free of dust. 7. Position sockets XM4 and XP4 so that they are located on the underside after motor A4 has been inserted into the robot arm. 8. Pick up motor A4 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM4 and XP4 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). 538/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-20: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 9.4.4 Concluding work The following concluding work must be carried out: • Move A4, A5 and A6 of the robot and look out for irregularities. • Carry out mastering of A4, A5 and A6. Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity mode (T1). 9.5 Exchanging motor A5 Description The following instructions describe the exchange of the motor. This description applies to floor-mounted robots. If the robot is installed in an inclined or suspended position, the procedure is to be applied analogously. During removal of the motor, the robot can independently move about this axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end position (e.g. buffer) can be used to secure against motions. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 539/651 Repair KR QUANTEC-2 Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Brush - SEMD/MEMD mastering kit 0000-228-936 Material The following material is required: Designation Article number Quantity SPP motor 1.7kW L0 ME 0000-336-054 1 0000-334-482 1 0000-362-271 1 For the following machines: • • • • • KR KR KR KR KR 120 120 150 150 180 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 SPP motor 2.5kW L0 ME For the following machines: • • • • • • • • • KR KR KR KR KR KR KR KR KR 210 210 210 240 240 250 250 300 300 R2700-2 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 C C C C SPP motor 1.7kW L0 ME For the following machines: • • • • • 540/651 | www.kuka.com KR KR KR KR KR 120 120 150 150 180 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 F F F F F MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Designation Article number Quantity SPP motor 2.5kW L0 ME 0000-362-287 1 For the following machines: • • • • • KR KR KR KR KR 210 210 240 250 300 R2700-2 R3100-2 R2900-2 R2700-2 R2700-2 F F F F F Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot must be prevented from tipping. If necessary, fasten the robot to the mounting base. • The robot is secured against axis motions. • There is no hazard posed by system components. • Tools have been removed. Work safety WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 541/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cause burns. • Avoid contact. • Take appropriate safety precautions, e.g. wear protective gloves. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.5.1 Removing motor A5 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM5 and XP5 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A5. 3. Release motor A5 and pull it out together with connecting shaft A5, being careful not to tilt it. 4. Set down motor A5 together with connecting shaft A5. 542/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-21: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 5. Pull connecting shaft A5 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 543/651 Repair KR QUANTEC-2 Fig. 9-22: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.5.2 Preparing the new motor A4 - A5 for installation Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Clean the involute toothing of motor and connecting shaft before installation and apply a thin but continuous coat of Microlube GL 261 grease. 2. Clean the mounting surface for the motor. 3. Check the condition of the compression spring and, if applicable, backup ring on the motor shaft. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. In the case of damage and/or wear, the compression spring must be exchanged. 544/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-23: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 9.5.3 Installing motor A5 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A5 and motor shaft A5, and check for wear. In the case of damage and/or wear, connecting shaft A5 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A5. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A5 onto motor shaft A5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 545/651 Repair KR QUANTEC-2 Fig. 9-24: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 6. The mounting surfaces (motor A5 and robot arm) must be dry and free of dust. 7. Position sockets XM5 and XP5 so that they are located on the underside after motor A5 has been inserted into the robot arm. 8. Pick up motor A5 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM5 and XP5 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). 546/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-25: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 9.5.4 Concluding work The following concluding work must be carried out: • Move A4, A5 and A6 of the robot and look out for irregularities. • Carry out mastering of A4, A5 and A6. Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity mode (T1). 9.6 Exchanging motor A6 Description The following instructions describe the exchange of the motor. This description applies to floor-mounted robots. If the robot is installed in an inclined or suspended position, the procedure is to be applied analogously. During removal of the motor, the robot can independently move about this axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end position (e.g. buffer) can be used to secure against motions. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 547/651 Repair KR QUANTEC-2 Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Crane with sufficient load-bearing capacity - Rope sling with sufficient load-bearing capacity - Brush - SEMD/MEMD mastering kit 0000-228-936 Material The following material is required: Designation Article number Quantity SPP motor 2.5kW L1 ME 0000-334-483 1 0000-362-270 1 For the following machines: • • • • • • • • • • • • • • KR KR KR KR KR KR KR KR KR KR KR KR KR KR 120 120 150 150 180 210 210 210 240 240 250 250 300 300 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 C C C C SPP motor 2.5kW L0 ME For the following machines: • • • • • • • • • • 548/651 | www.kuka.com KR KR KR KR KR KR KR KR KR KR 120 120 150 150 180 210 210 240 250 300 R2700-2 R3100-2 R2700-2 R3100-2 R2900-2 R2700-2 R3100-2 R2900-2 R2700-2 R2700-2 F F F F F F F F F F MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot must be prevented from tipping. If necessary, fasten the robot to the mounting base. • The robot is secured against axis motions. • There is no hazard posed by system components. • Tools have been removed. Work safety DANGER Danger to life and limb due to defective or unsuitable load suspension devices If defective or non-approved load suspension devices are used, the load may fall off or start to swing. Failure to observe this can lead to death, injury or property damage. • Before using load suspension devices, check for defects (e.g. damage, corrosion, deformation, wear, cracks) and exchange components if necessary. • Use only inspected and approved load suspension devices. • Use only load suspension devices with a sufficient load-bearing capacity. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 549/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cause burns. • Avoid contact. • Take appropriate safety precautions, e.g. wear protective gloves. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.6.1 Removing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM4 and XP4 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A4. 3. Release motor A4 and pull it out together with connecting shaft A4, being careful not to tilt it. 4. Set down motor A4 together with connecting shaft A4. 550/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-26: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 5. Pull connecting shaft A4 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 551/651 Repair KR QUANTEC-2 Fig. 9-27: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.6.2 Removing motor A5 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM5 and XP5 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A5. 3. Release motor A5 and pull it out together with connecting shaft A5, being careful not to tilt it. 4. Set down motor A5 together with connecting shaft A5. 552/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-28: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 5. Pull connecting shaft A5 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 553/651 Repair KR QUANTEC-2 Fig. 9-29: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.6.3 Removing the in-line wrist Procedure 1. Fasten the rope sling to the in-line wrist and to the crane. WARNING The in-line wrist and the arm may be damaged or persons injured if the in-line wrist is not safely secured. The in-line wrist weighs approx. 100 kg. The crane and rope must therefore be able to support this load safely. 2. Move the crane until the weight of the in-line wrist is supported by the crane. 3. Release and unplug motor connectors XM6 and XP6 from the plate. 4. Unscrew 4 M6x12-8.8-A2K Allen screws from the plate. 5. Release and unplug motor connectors XM6 and XP6 and, if applicable, purging air from the back of the plate. 554/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-30: In-line wrist connectors 1 Plate 2 Connector XP6 3 M6x12-8.8-A2K Allen screws 4 Purging air (for Foundry only) 5 Connector XM6 6. Unscrew 20 M10x200-10.9 Allen screws from the in-line wrist. 7. Carefully release the in-line wrist from the robot arm and pull it out using the crane. Do not tilt it when removing it. The gap between the robot arm and the in-line wrist must be uniform at all times around the entire circumference. Also move the crane at the same time as pulling out the inline wrist. Fig. 9-31: In-line wrist 1 Connector XM6 2 Connector XP6 3 In-line wrist 4 Rope sling 5 M10x200-10.9 Allen screw MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 555/651 Repair KR QUANTEC-2 6 Robot arm 8. Place the in-line wrist on a suitable support surface and remove the rope sling. 9. If the in-line wrist is not to be reinstalled, it must be protected against corrosion before being put into storage. 9.6.4 Removing motor A6 Procedure 1. Unscrew and remove 4 M8x30-8.8-A2K Allen screws from motor A6. 2. Unfasten and remove motor A6. Fig. 9-32: In-line wrist with motor A6 1 In-line wrist 2 M8x30-8.8-A2K Allen screw 3 Motor A6 4 Connector XP6 5 Connector XM6 3. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.6.5 Preparing a new motor for installation Procedure 1. Clean the involute toothing of motor A6 and gear unit before installation and apply a thin but continuous coat of Microlube GL 261 grease. 2. Clean the mounting surface for the motor. 3. Check the condition of the compression spring and, if applicable, backup ring on the motor shaft. 556/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. In the case of damage and/or wear, the compression spring must be exchanged. Fig. 9-33: Motor A6 1 Motor A6 2 M8x30-8.8 Allen screw 3 Compression spring 9.6.6 Installing motor A6 Procedure 1. Motor connectors XM6 and XP6 are positioned in such a way that they are located diagonally on the bottom left-hand side after the motor has been inserted. 2. Insert motor A6 into the in-line wrist; do not tilt during installation and ensure correct location (toothing). Insertion of motor can be facilitated by turning it gently about its rotational axis. 3. Insert 4 M8x30-8.8-A2K Allen screws. Increase the tightening torque to the specified value in several stages. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 557/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 Fig. 9-34: In-line wrist with motor A6 1 In-line wrist 2 M8x30-8.8-A2K Allen screw 3 Motor A6 4 Connector XP6 5 Connector XM6 4. Mark the screws with screw locking varnish. 9.6.7 Installing the in-line wrist Procedure 1. Fasten the rope sling to the in-line wrist. WARNING The in-line wrist and the arm may be damaged or persons injured if the in-line wrist is not safely secured. The in-line wrist weighs approx. 100 kg. The crane and rope must therefore be able to support this load safely. 2. Pick up the in-line wrist with the crane, bring it to the installation site and ensure that axes 4 and 5 are in their zero positions. 3. Insert the in-line wrist into the robot arm, introducing the motor cables into the robot arm in such a way that they are not wound around the connecting shafts. Do not tilt when inserting and move the crane simultaneously. The gap between the robot arm and the in-line wrist must be uniform at all times around the entire circumference. 4. Route motor connectors XM6 and XP6 through the aperture in the robot arm and connect them to the back of the plate. 5. Insert 20 new M10x200-10.9 Allen screws into the in-line wrist. 558/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 6. Tighten 20 M10x200-10.9 Allen screws alternately with the torque wrench. Increase the tightening torque to the specified value in several stages. 7. Remove the rope sling. Fig. 9-35: In-line wrist 1 Connector XM6 2 Connector XP6 3 In-line wrist 4 Rope sling 5 M10x200-10.9 Allen screw 6 Robot arm 8. Fasten the plate to the robot arm with 4 M6x12-8.8-A2K Allen screws. 9. Connect connectors XM6 and XP6 and, if applicable, purging air to the front of the plate. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-36: In-line wrist connectors 1 Plate 2 Connector XP6 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 559/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 3 M6x12-8.8-A2K Allen screws 4 Purging air (for Foundry only) 5 Connector XM6 9.6.8 Installing motor A5 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A5 and motor shaft A5, and check for wear. In the case of damage and/or wear, connecting shaft A5 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A5. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A5 onto motor shaft A5. Fig. 9-37: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 560/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 6. The mounting surfaces (motor A5 and robot arm) must be dry and free of dust. 7. Position sockets XM5 and XP5 so that they are located on the underside after motor A5 has been inserted into the robot arm. 8. Pick up motor A5 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM5 and XP5 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-38: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 561/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 9.6.9 Installing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A4 and motor shaft A4, and check for wear. In the case of damage and/or wear, connecting shaft A4 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A4. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A4 onto motor shaft A4. Fig. 9-39: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 6. The mounting surfaces (motor A4 and robot arm) must be dry and free of dust. 7. Position sockets XM4 and XP4 so that they are located on the underside after motor A4 has been inserted into the robot arm. 562/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 8. Pick up motor A4 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM4 and XP4 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-40: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 9.6.10 Concluding work The following concluding work must be carried out: • Move A4, A5 and A6 of the robot and look out for irregularities. • Carry out mastering of A4, A5 and A6. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 563/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity mode (T1). 9.7 Exchanging the in-line wrist Description The following describes the exchange of the in-line wrist. All the in-line wrist variants are installed in the same way, irrespective of the payload or arm length. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Crane with sufficient load-bearing capacity - Rope sling with sufficient load-bearing capacity - Brush - SEMD/MEMD mastering kit 0000-228-936 Material The specified spare parts packages (SPP) differ in color, but are functionally identical. The code "KUKAO" corresponds to KUKA orange 2567; the SPP without a color code corresponds to the current standard color KUKA Industrial Orange (RAL 2009). The color of the robot can be found in the shipping documents. The following material is required: Robot Designation Article number • • • • • KR KR KR KR KR 120 120 150 150 210 R2700-2 R3100-2 R2700-2 R3100-2 R2700-2 SPP IW 210 Quantec-2 Std -C -K 0000-388-560 • • • • • • • • KR KR KR KR KR KR KR KR 210 210 240 240 250 250 300 300 R3100-2 R3100-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 SPP IW 300 Quantec-2 Std -C -K 0000-388-559 564/651 | www.kuka.com Quantity 1 SPP IW 210 Quantec-2 Std -C -K 0000-334-481 KUKAO C 1 SPP IW 300 Quantec-2 Std -C -K 0000-336-010 KUKAO C C C MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Robot Designation Article number Quantity 1 • • • • KR KR KR KR 120 120 150 210 R2700-2 R3100-2 R2700-2 R2700-2 F F F F SPP IW 210 F 0000-388-561 SPP IW 210 F KUKAO 0000-362-268 • • • • • KR KR KR KR KR 180 210 240 250 300 R2900-2 R3100-2 R2900-2 R2700-2 R2700-2 F F F F F SPP IW 300 F 0000-388-562 SPP IW 300 F KUKAO 0000-362-269 1 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Preconditions • The controller is switched off and secured to prevent unauthorized persons from switching it on again. • The arm is in the horizontal position. • Axes 4, 5 and 6 should, if possible, be in their zero positions. • Payload (tool or device) has been removed from the in-line wrist. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 565/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 Work safety WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. DANGER Danger to life and limb due to defective or unsuitable load suspension devices If defective or non-approved load suspension devices are used, the load may fall off or start to swing. Failure to observe this can lead to death, injury or property damage. • Before using load suspension devices, check for defects (e.g. damage, corrosion, deformation, wear, cracks) and exchange components if necessary. • Use only inspected and approved load suspension devices. • Use only load suspension devices with a sufficient load-bearing capacity. 9.7.1 Removing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM4 and XP4 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A4. 3. Release motor A4 and pull it out together with connecting shaft A4, being careful not to tilt it. 4. Set down motor A4 together with connecting shaft A4. 566/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-41: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 5. Pull connecting shaft A4 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 567/651 Repair KR QUANTEC-2 Fig. 9-42: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.7.2 Removing motor A5 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM5 and XP5 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A5. 3. Release motor A5 and pull it out together with connecting shaft A5, being careful not to tilt it. 4. Set down motor A5 together with connecting shaft A5. 568/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-43: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 5. Pull connecting shaft A5 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 569/651 Repair KR QUANTEC-2 Fig. 9-44: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.7.3 Removing the in-line wrist Procedure 1. Fasten the rope sling to the in-line wrist and to the crane. WARNING The in-line wrist and the arm may be damaged or persons injured if the in-line wrist is not safely secured. The in-line wrist weighs approx. 100 kg. The crane and rope must therefore be able to support this load safely. 2. Move the crane until the weight of the in-line wrist is supported by the crane. 3. Release and unplug motor connectors XM6 and XP6 from the plate. 4. Unscrew 4 M6x12-8.8-A2K Allen screws from the plate. 5. Release and unplug motor connectors XM6 and XP6 and, if applicable, purging air from the back of the plate. 570/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-45: In-line wrist connectors 1 Plate 2 Connector XP6 3 M6x12-8.8-A2K Allen screws 4 Purging air (for Foundry only) 5 Connector XM6 6. Unscrew 20 M10x200-10.9 Allen screws from the in-line wrist. 7. Carefully release the in-line wrist from the robot arm and pull it out using the crane. Do not tilt it when removing it. The gap between the robot arm and the in-line wrist must be uniform at all times around the entire circumference. Also move the crane at the same time as pulling out the inline wrist. Fig. 9-46: In-line wrist 1 Connector XM6 2 Connector XP6 3 In-line wrist 4 Rope sling 5 M10x200-10.9 Allen screw MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 571/651 Repair KR QUANTEC-2 6 Robot arm 8. Place the in-line wrist on a suitable support surface and remove the rope sling. 9. If the in-line wrist is not to be reinstalled, it must be protected against corrosion before being put into storage. 9.7.4 Removing motor A6 Procedure 1. Unscrew and remove 4 M8x30-8.8-A2K Allen screws from motor A6. 2. Unfasten and remove motor A6. Fig. 9-47: In-line wrist with motor A6 1 In-line wrist 2 M8x30-8.8-A2K Allen screw 3 Motor A6 4 Connector XP6 5 Connector XM6 3. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.7.5 Preparing the new in-line wrist Procedure 1. Remove all protective coatings and oil from new in-line wrist, if applicable. 2. Clean all toothing before installation and apply a thin but continuous coat of Microlube GL 261 grease. 572/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 NOTICE When installing the in-line wrist, it must be ensured that the toothing of the in-line wrist and connecting shafts is not damaged. Increased wear and premature failure may result. 9.7.6 Installing motor A6 Procedure 1. Motor connectors XM6 and XP6 are positioned in such a way that they are located diagonally on the bottom left-hand side after the motor has been inserted. 2. Insert motor A6 into the in-line wrist; do not tilt during installation and ensure correct location (toothing). Insertion of motor can be facilitated by turning it gently about its rotational axis. 3. Insert 4 M8x30-8.8-A2K Allen screws. Increase the tightening torque to the specified value in several stages. Fig. 9-48: In-line wrist with motor A6 1 In-line wrist 2 M8x30-8.8-A2K Allen screw 3 Motor A6 4 Connector XP6 5 Connector XM6 4. Mark the screws with screw locking varnish. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 573/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 9.7.7 Installing the in-line wrist Procedure 1. Fasten the rope sling to the in-line wrist. WARNING The in-line wrist and the arm may be damaged or persons injured if the in-line wrist is not safely secured. The in-line wrist weighs approx. 100 kg. The crane and rope must therefore be able to support this load safely. 2. Pick up the in-line wrist with the crane, bring it to the installation site and ensure that axes 4 and 5 are in their zero positions. 3. Insert the in-line wrist into the robot arm, introducing the motor cables into the robot arm in such a way that they are not wound around the connecting shafts. Do not tilt when inserting and move the crane simultaneously. The gap between the robot arm and the in-line wrist must be uniform at all times around the entire circumference. 4. Route motor connectors XM6 and XP6 through the aperture in the robot arm and connect them to the back of the plate. 5. Insert 20 new M10x200-10.9 Allen screws into the in-line wrist. 6. Tighten 20 M10x200-10.9 Allen screws alternately with the torque wrench. Increase the tightening torque to the specified value in several stages. 7. Remove the rope sling. Fig. 9-49: In-line wrist 1 Connector XM6 2 Connector XP6 3 In-line wrist 4 Rope sling 5 M10x200-10.9 Allen screw 6 Robot arm 8. Fasten the plate to the robot arm with 4 M6x12-8.8-A2K Allen screws. 9. Connect connectors XM6 and XP6 and, if applicable, purging air to the front of the plate. The pins and coding elements of the connectors 574/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-50: In-line wrist connectors 1 Plate 2 Connector XP6 3 M6x12-8.8-A2K Allen screws 4 Purging air (for Foundry only) 5 Connector XM6 9.7.8 Installing motor A5 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A5 and motor shaft A5, and check for wear. In the case of damage and/or wear, connecting shaft A5 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A5. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A5 onto motor shaft A5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 575/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 Fig. 9-51: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 6. The mounting surfaces (motor A5 and robot arm) must be dry and free of dust. 7. Position sockets XM5 and XP5 so that they are located on the underside after motor A5 has been inserted into the robot arm. 8. Pick up motor A5 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM5 and XP5 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). 576/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-52: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 9.7.9 Installing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A4 and motor shaft A4, and check for wear. In the case of damage and/or wear, connecting shaft A4 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A4. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A4 onto motor shaft A4. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 577/651 Repair KR QUANTEC-2 Fig. 9-53: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 6. The mounting surfaces (motor A4 and robot arm) must be dry and free of dust. 7. Position sockets XM4 and XP4 so that they are located on the underside after motor A4 has been inserted into the robot arm. 8. Pick up motor A4 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM4 and XP4 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). 578/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-54: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 9.7.10 Concluding work The following concluding work must be carried out: • Adapt the MAMES values. If using KSS 8.3, the plug-in KUKA.WristMamesOffset is required for this. • Move A4, A5 and A6 of the robot and look out for irregularities. • Carry out mastering of A4, A5 and A6. Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity (T1) mode. 9.8 Exchanging the connecting shafts Description The following instructions describe the exchange of connecting shafts A4 and A5. The connecting shafts must always be exchanged as a pair. This MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 579/651 KR QUANTEC-2 Repair description applies to floor-mounted robots. If the robot is installed in an inclined or suspended position, the procedure is to be applied analogously. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 5 Nm to 50 Nm - Socket wrench set - Brush - SEMD/MEMD mastering kit 0000-228-936 Material The following material is required: Designation Article number Quantity SPP shaft Quantec-2 770 COS 0000-334-487 1 0000-336-055 1 For the following machines: • • • • • • • • • • • • • • • • • KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR 120 120 150 150 180 180 210 210 240 240 240 250 250 250 300 300 300 R2700-2 R2700-2 R2700-2 R2700-2 R2900-2 R2900-2 R2700-2 R2700-2 R2900-2 R2900-2 R2900-2 R2700-2 R2700-2 R2700-2 R2700-2 R2700-2 R2700-2 F F F F F C F C F C SPP shaft Quantec-2 970 COS For the following machines: • • • • • • • 580/651 | www.kuka.com KR KR KR KR KR KR KR 120 120 150 150 210 210 210 R3100-2 R3100-2 R3100-2 R3100-2 R3100-2 R3100-2 R3100-2 F F F C MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot must be prevented from tipping. If necessary, fasten the robot to the mounting base. • The robot is secured against axis motions. • There is no hazard posed by system components. • Tools have been removed. Work safety WARNING Danger to life and limb due to live parts When work is performed on this system, live parts can lead to unintentional motions of the robot, positioner or other components. Failure to observe this may result in physical injuries and damage to property. • If work is carried out on an operable system, the main switch on the control cabinet must be turned to the OFF position and secured with a padlock to prevent unauthorized persons from switching it on again. • Inform the persons involved by means of a sign (e.g. affix a warning sign). • Warn all persons concerned before putting the system back into operation. CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cause burns. • Avoid contact. • Take appropriate safety precautions, e.g. wear protective gloves. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 581/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.8.1 Removing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM4 and XP4 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A4. 3. Release motor A4 and pull it out together with connecting shaft A4, being careful not to tilt it. 4. Set down motor A4 together with connecting shaft A4. Fig. 9-55: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 582/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 5. Pull connecting shaft A4 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. Fig. 9-56: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.8.2 Removing motor A5 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. Release and unplug connectors XM5 and XP5 at the sockets. 2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A5. 3. Release motor A5 and pull it out together with connecting shaft A5, being careful not to tilt it. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 583/651 Repair KR QUANTEC-2 4. Set down motor A5 together with connecting shaft A5. Fig. 9-57: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 5. Pull connecting shaft A5 off motor shaft. 6. Take compression spring and, if applicable, back-up ring off the motor shaft. 584/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-58: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 7. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.8.3 Preparing the new connecting shafts Procedure 1. Remove corrosion protection from the new connecting shafts, if applicable. 2. Clean all toothing before installation and apply a thin but continuous coat of Microlube GL 261 grease. NOTICE When installing the in-line wrist, it must be ensured that the toothing of the in-line wrist and connecting shafts is not damaged. Increased wear and premature failure may result. 9.8.4 Installing motor A5 Description The following work steps are identical for motor A4 and motor A5. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 585/651 Repair KR QUANTEC-2 Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A5 and motor shaft A5, and check for wear. In the case of damage and/or wear, connecting shaft A5 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A5. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A5 onto motor shaft A5. Fig. 9-59: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 6. The mounting surfaces (motor A5 and robot arm) must be dry and free of dust. 7. Position sockets XM5 and XP5 so that they are located on the underside after motor A5 has been inserted into the robot arm. 8. Pick up motor A5 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 586/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM5 and XP5 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-60: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 9.8.5 Installing motor A4 Description The following work steps are identical for motor A4 and motor A5. Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Clean the toothing on connecting shaft A4 and motor shaft A4, and check for wear. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 587/651 Repair KR QUANTEC-2 KR QUANTEC-2 Repair In the case of damage and/or wear, connecting shaft A4 must be exchanged. 3. Apply a thin but continuous coat of Microlube GL 261 to the toothing on connecting shaft A4. 4. Mount compression spring on motor shaft A5. If there was a back-up ring on the motor shaft when the motor was removed, it must be disposed of and not reused on installing a new motor. 5. Push connecting shaft A4 onto motor shaft A4. Fig. 9-61: Connecting shafts A4 and A5 1 Motor A5 2 Motor A4 3 Motor shaft with involute toothing 4 Compression spring 5 Connecting shaft A4 6. The mounting surfaces (motor A4 and robot arm) must be dry and free of dust. 7. Position sockets XM4 and XP4 so that they are located on the underside after motor A4 has been inserted into the robot arm. 8. Pick up motor A4 and insert it into the robot arm, being careful not to tilt it and ensuring that the connecting shafts (toothing) are correctly engaged in the in-line wrist. Insertion of motor can be facilitated by turning it gently about its rotational axis. 9. Insert 4 M8x25-8.8-A2K Allen screws. 10. Tighten 4 M8x25-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 11. Plug connectors XM4 and XP4 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When in588/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 serting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-62: Motors A4 and A5 1 Robot arm 2 M8x25-8.8-A2K Allen screw 3 Motor A5 4 Connector XM5 5 Connector XP5 6 Connector XM4 7 Connector XP4 8 Motor A4 9.8.6 Concluding work The following concluding work must be carried out: • Move A4, A5 and A6 of the robot and look out for irregularities. • Carry out mastering of A4, A5 and A6. Detailed information about mastering can be found in the system software documentation. • Test the program in Manual Reduced Velocity mode (T1). 9.9 Description of the electrical installations Overview The electrical installations of the robot consist of: • Cable set • RDC box MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 589/651 Repair KR QUANTEC-2 Repair KR QUANTEC-2 Description The electrical installations consist of the cable set from A1 to A6 as well as the electronic modules, such as the RDC and EDS. The cable set includes all the supply and control cables for the motors of axes 1 to 6 as well as the cables for the protective circuit. All the connections on the motors are screwed plug-and-socket connections. RDC and EDS are explained in more detail in the operating instructions of the robot controller. The interface for connecting the connecting cables to the robot is located on the base frame at the rear of the robot. The connecting cables from the controller (motor cable X30, data cable X31, the ground conductor and, if applicable, the cables for external axes) are connected to it by means of connectors. The selected routing of cables and hoses within the robot arm ensures that the lines are guided without strain or kinking throughout the entire motion range of the robot. The following diagram gives an overview of the installation and routing of the cables and hoses on the manipulator (>>> Fig. 9-63). NOTICE Break in cables when modifying the cable set The cable set is designed to stretch sufficiently with each robot motion. Additional attachments can place a heavy load on the cable set and thus damage it. Error messages and damage to property could result. • Do not attach any other lines to the cable set; use an external energy supply system if necessary. • Do not fix the cable set in place with cable straps, Velcro cable straps or the like. • Keep foreign bodies away. 590/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-63: Overview of electrical installations 1 Motor A6 5 Motor A2 2 Motor A5 6 Motor A1 3 Motor A4 7 RDC box 4 Motor A3 Wiring diagrams Designation Connection Figure Wiring diagram A1 XM1 (>>> Fig. 9-64) Wiring diagram A2 XM2 (>>> Fig. 9-65) Wiring diagram A3 XM3 (>>> Fig. 9-66) Wiring diagram A4 XM4 (>>> Fig. 9-67) Wiring diagram A5 XM5 (>>> Fig. 9-68) Wiring diagram A6 XM6 (>>> Fig. 9-69) Data cable RDC X31 RDC X31 (>>> Fig. 9-70) Data cable RDC X32 RDC X32 (>>> Fig. 9-71) Data cable, external axis X7 XP7 (>>> Fig. 9-72) Data cable, external axis X8 XP8 (>>> Fig. 9-72) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 591/651 Repair KR QUANTEC-2 Designation Connection Figure Protective circuit Ring cable lug (>>> Fig. 9-73) Fig. 9-64: Wiring diagram A1 592/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-65: Wiring diagram A2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 593/651 Repair KR QUANTEC-2 Fig. 9-66: Wiring diagram A3 594/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-67: Wiring diagram A4 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 595/651 Repair KR QUANTEC-2 Fig. 9-68: Wiring diagram A5 596/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 Fig. 9-69: Wiring diagram A6 Fig. 9-70: Wiring diagram, RDC X31 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 597/651 Repair KR QUANTEC-2 Fig. 9-71: Wiring diagram, RDC X32 Fig. 9-72: Wiring diagram, data cable X7/X8 - XP7/XP8 Fig. 9-73: Wiring diagram, protective circuit 598/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Repair KR QUANTEC-2 1 Ground conductor, arm – rotating column Cross-section: 4 mm2 2 Ground conductor, RDC – rotating column Cross-section: 4 mm2 3 Ground conductor, PE connection plate – base frame Cross-section: 4 mm2 4 Ground conductor, PE connection plate – rotating column Cross-section: 4 mm2 5 2x external ground conductor (KRC/system) Cross-section: 16 mm2 6 Ground conductor, PE connection plate – PE holding plate Cross-section: 4 mm2 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 599/651 Repair KR QUANTEC-2 600/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 10 Decommissioning, storage and disposal 10.1 Decommissioning Description This section describes all the work required for decommissioning the robot if the robot is to be removed from the system. After decommissioning, it is prepared for storage or for transportation to a different location. Following its removal, the robot can be transported by means of transport tackle and crane or by fork lift truck. Equipment The following equipment is required: Designation Article number Lifting tackle/rope sling with sufficient load-bearing capacity 0000-342-903 Crane with sufficient load-bearing capacity - Fork lift truck with sufficient load-bearing capacity - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Precondition • The removal site must be accessible with a crane or with a fork lift truck for transportation. • There is no hazard posed by system components. Work safety WARNING Danger to life and limb due to unintended robot motions When carrying out the following work, the robot must be moved several times between the individual work steps. Unintentional movements of the robot can cause death, serious injury or material damage. • While work is being carried out on the robot, it must always be secured by actuating the EMERGENCY STOP device. • If work is carried out on an operational robot that is switched on, the robot must only be moved at reduced velocity. It must be possible to stop the robot at any time by actuating an EMERGENCY STOP device. Operation must be limited to what is absolutely necessary. • Warn all persons concerned before switching on and moving the robot. 10.1.1 Moving the robot into its transport position Procedure 1. Secure the robot by pressing the EMERGENCY STOP device. 2. Remove tools and equipment. 3. Put the robot into operation and move it into the transport position. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 601/651 Decommissioning, storage and disposal KR QUANTEC-2 Decommissioning, storage and disposal KR QUANTEC-2 4. Secure the robot by activating the EMERGENCY STOP device and then shut down the robot. Transport position A1 0 ° A2 -137 ° A3 160 ° A4 0 ° A5 -105 ° A6 0 ° Fig. 10-1: Transport position 10.1.2 Removing the robot Procedure 1. Release and disconnect the peripheral connections. 2. Release and disconnect the motor cable and data cable connectors (>>> Fig. 10-2). 3. Unscrew the hexagon nut from the ground conductor, take off the washers and lock washers and pull off the ground conductor. 4. Unscrew and remove the 8 hexagon bolts and conical spring washers. 5. Lift the robot vertically off the mounting surface and transport it away. Take care not to damage the two pins when lifting off the robot. CAUTION Risk of injury due to abrupt detachment of the robot If the robot is caught on the mounting surface, it may come free abruptly. Injuries or damage to property may result. ‒ Remove the fastening materials completely. ‒ Remove any adhesives. 602/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Decommissioning, storage and disposal KR QUANTEC-2 Fig. 10-2: Removing the robot 10.1.3 1 Fork slots 4 Ground conductor 2x 2 Hexagon bolts 5 Motor cable 3 Pin 6 Data cable Concluding work The following concluding work must be carried out: • Prepare the robot for storage if the robot is not to be reinstalled. 10.2 Storage Description For storage, the robot must be removed, cleaned and suitably covered. Storage location The storage location must meet the following requirements: • • • • • • • Virtually dry and free of dust Avoid temperature fluctuations Avoid wind and drafts Avoid condensation No exposure to direct sunlight Maintain the permissible temperature ranges for storage The packaging film cannot be damaged. Equipment The following equipment is required: MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 603/651 Decommissioning, storage and disposal KR QUANTEC-2 Designation Article number Lifting tackle/rope sling with sufficient load-bearing capacity 0000-342-903 Crane with sufficient load-bearing capacity - Fork lift truck with sufficient load-bearing capacity - Permissible cleaning tools (e.g. cloths, brushes) - Material The following material is required: Designation Article number Quantity Covers that cannot detach themselves and which can withstand the expected environmental conditions - Cleaning agent solvent-free, water-soluble, non-flammable, non-aggressive, no steam, no refrigerants - - Precondition • Loose parts or parts that might knock against other parts have been removed from the robot. • Tools and equipment have been removed. Work safety WARNING Danger to life and limb due to unintended robot motions When carrying out the following work, the robot must be moved several times between the individual work steps. Unintentional movements of the robot can cause death, serious injury or material damage. • While work is being carried out on the robot, it must always be secured by actuating the EMERGENCY STOP device. • If work is carried out on an operational robot that is switched on, the robot must only be moved at reduced velocity. It must be possible to stop the robot at any time by actuating an EMERGENCY STOP device. Operation must be limited to what is absolutely necessary. • Warn all persons concerned before switching on and moving the robot. 10.2.1 Moving the robot into its transport position Procedure 1. 2. 3. 4. 604/651 | www.kuka.com Secure the robot by pressing the EMERGENCY STOP device. Remove tools and equipment. Put the robot into operation and move it into the transport position. Secure the robot by activating the EMERGENCY STOP device and then shut down the robot. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Decommissioning, storage and disposal KR QUANTEC-2 Transport position A1 0 ° A2 -137 ° A3 160 ° A4 0 ° A5 -105 ° A6 0 ° Fig. 10-3: Transport position 10.2.2 Removing the robot Procedure 1. Release and disconnect the peripheral connections. 2. Release and disconnect the motor cable and data cable connectors (>>> Fig. 10-4). 3. Unscrew the hexagon nut from the ground conductor, take off the washers and lock washers and pull off the ground conductor. 4. Unscrew and remove the 8 hexagon bolts and conical spring washers. 5. Lift the robot vertically off the mounting surface and transport it away. Take care not to damage the two pins when lifting off the robot. CAUTION Risk of injury due to abrupt detachment of the robot If the robot is caught on the mounting surface, it may come free abruptly. Injuries or damage to property may result. ‒ Remove the fastening materials completely. ‒ Remove any adhesives. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 605/651 Decommissioning, storage and disposal KR QUANTEC-2 Fig. 10-4: Removing the robot 10.2.3 1 Fork slots 4 Ground conductor 2x 2 Hexagon bolts 5 Motor cable 3 Pin 6 Data cable Cleaning Procedure 1. Shut down the robot. 2. If necessary, shut adjacent system components down and lock them. 3. Remove enclosures if this is necessary in order to carry out the cleaning work. 4. Clean the robot. 5. Fully remove all cleaning agents from the robot. 6. Clean any areas of corrosion and reapply corrosion protection. 7. Install any safety equipment that has been removed. 8. Put back in place any enclosures that have been removed. 10.2.4 Preparing for storage Procedure 1. 2. 3. 4. Perform a visual inspection of the robot. Remove any foreign bodies. Remove any corrosion. Attach all covers to the robot and check that the seals are correctly in place. 5. Seal off electrical connections with suitable covers. 6. Seal hose connections by suitable means. 7. Cover the robot with plastic film and seal it at the base frame against dust. If necessary, add a desiccant beneath the sheeting. 606/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 10.2.5 Concluding work No concluding work is required. 10.3 Disposal When the manipulator reaches the end of its useful life, it can be removed from the system and dismantled, and the materials can be disposed of properly by type. The following table provides an overview of the materials used in the manipulator. All plastic components are marked with a material designation and must be disposed of accordingly. WARNING The hydropneumatic counterbalancing system on the robot is filled with nitrogen and hydraulic oil under pressure; improper handling can lead to personal injury and damage to property. If the hydropneumatic counterbalancing system to be disposed of, it must first be properly depressurized. Only pressure-free counterbalancing systems may be authorized for disposal. Material Subassembly, component Additional information Metal Cast-iron material Base frame, rotating column, link arm, arm, in-line wrist Copper Cables, wires Light alloy casting Spur gear housing, swivel housing Steel Gear units, screws and washers, connecting shafts, bearings, holder plates Electrical parts Electronic components, such as RDC Dispose of as electrical scrap without disassembling. Motors Dispose of motors without dismantling. Plastics ETFE Flexible tube, protective fabric sleeve PA 6, PA R AB Hinged clamps, flexible tubes PE 500 End stop buffers PU Hoses PUR Cable sheaths Viton, FKM, FPM O-rings EPDM/TPE Clamping pieces, RSGU clips POM/PP Sliding elements MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 607/651 Decommissioning, storage and disposal KR QUANTEC-2 Decommissioning, storage and disposal KR QUANTEC-2 Material Subassembly, component Additional information Auxiliary substances and consumables Gear oil Gear units Optigear Synt. ALR 150 Hydraulic oil Counterbalancing system Hyspin ZZ 46 hydraulic oil Lubricating grease Counterbalancing system, bearing on arm / link arm LGEP 2 lubricating grease Lubricating grease Gear teeth Microlube GL 261 grease Up-to-date safety data sheets must be requested from the manufacturers of auxiliary and operating materials. Further information about the auxiliary substances and consumables used can be found under: (>>> 12.2 "Auxiliary and operating materials used" Page 636) 608/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Options KR QUANTEC-2 11 Options 11.1 Release device Description The release device can be used to move the manipulator manually after an accident or malfunction. The release device can be used for the motors of axes A1 to A5. It cannot be used for axis A6, as this motor is not accessible. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people). In the case of floor-mounted robots, the release device can be mounted on the base frame. For ceiling-mounted robots, the release device must be mounted on the cell in a clearly visible position. The assembly includes a ratchet, a TORX key wrench and two sets of plates with one plate for each motor and a plate on the cast housing near the respective motor. The plates specify the direction of rotation for the ratchet and show the corresponding direction of motion of the manipulator. In order to move the manipulator without drive energy in the event of an accident or malfunction, either a sufficient number of release devices or a sufficient amount of suitable standard tools (TORX key wrench TX25 or a size 8 flat-blade screwdriver and 12 mm combination wrench) must be available. Fig. 11-1: Product overview 1 Release device 2 TX25 TORX key wrench 3 Base frame Basic data Designation Article number Weight Release device 0000-341-621 approx. 3 kg Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. Start-up and recommissioning (>>> 11.1.1 "Starting up the release device" Page 610) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 609/651 Options KR QUANTEC-2 Maintenance If used for its intended purpose, the option requires minimal maintenance, i.e. visual inspections are recommended. In certain operating conditions, regular visual inspections may allow timely detection of changes. The nature and scope of the maintenance work depend very much on the specific area of application. This enables early detection of damage, thereby preventing failure of components and assemblies. Exchange damaged components or assemblies. Disposal When the release device reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations and, where possible, separated and sorted for recycling. 11.1.1 Starting up the release device Description The release device can be used for moving the manipulator after an accident or malfunction without drive energy. This section describes all work required to put the release device into operation. Installation of a floor-mounted robot is described. A release device for ceiling-mounted robots must be fastened to the cell wall. This option is only for use in exceptional circumstances and emergencies, e.g. for rescuing people. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench 5 Nm to 50 Nm - Material The following material is required: Designation Article number Quantity Release device 0000-341-621 1 or - 1 each 12 mm combination wrench and TORX key wrench TX25 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. 610/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 When the screws are first slackened they must be replaced with new ones. Precondition • The robot controller is switched off. • The robot is freely accessible. Work safety SAFETY INSTRUCTION The following procedure must be followed exactly! CAUTION Loss of mastering during movement without drive energy After moving a motor without drive energy, the axis is no longer mastered. Injuries or damage to property may result. • Remaster all axes. 11.1.1.1 Installing the release device Procedure 1. Unscrew 4 M8x20-8.8 Allen screws from the cover plate and remove the cover plate from the base frame (>>> Fig. 11-2). 2. Position the clip plate on the base frame, insert 4 M8x20-8.8 Allen screws and conical spring washers and fasten in place. Increase the tightening torque to the specified value in several stages. 3. Place the release device and key wrench on the clip plate. Fig. 11-2: Installing the release device 1 Release device 2 TX25 TORX key wrench 3 M8x20-8.8-A2K Allen screw (4x) 4 Conical spring washer (4x) 5 Clip plate MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 611/651 Options KR QUANTEC-2 Options KR QUANTEC-2 6 Cover plate 4. Attach the arrow adhesive labels to the cast housing in the vicinity of the respective motors as shown in the illustration (>>> Fig. 11-3). Fig. 11-3: Location of arrow adhesive labels, applicable to KR QUANTEC-2 and KR QUANTEC-2 K 1 Arrow adhesive label A1 2 Arrow adhesive label A2 3 Arrow adhesive label A3 4 Arrow adhesive label A4 5 Arrow adhesive label A5 11.1.1.2 Moving the manipulator without drive energy Procedure 1. Unscrew 4 M6x20 TORX slotted screws (TX25/slot size 8) and take the cover off the corresponding motor (using a flat-blade screwdriver, if necessary). 2. Push the release device (or combination wrench, size 12 mm) onto the corresponding motor and move the axis in the desired direction. It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis. Fig. 11-4: Motor with release device 612/651 | www.kuka.com 1 Motor 2 M6x20 TORX screw (TX25/size 8 slot) (4x) 3 Cover 4 Release device MA KR QUANTEC-2 V11 | Issued: 21.08.2023 3. Remove any dirt from the motor and cover. 4. Mount the cover on the motor and fit and tighten 4 M6x20 TORX slotted screws (TX25/slot size 8); MA = 4.5 Nm. 11.1.1.3 Concluding work The following concluding work must be carried out: • Master all axes. • Perform brake test. • Carry out a test run in T1 mode and look out for irregularities. 11.2 Cover of hollow shaft A1 Description The cover of hollow shaft A1 is a textile cover that is pulled over the rotating column to prevent dirt and foreign bodies from entering the hollow shaft. It does not offer additional IP protection. Fig. 11-5: Product overview 1 Outlet for energy supply system 2 Cover on hollow shaft A1 3 Aperture for energy supply system bracket with Velcro fastener Basic data Designation Article number Weight Cover on hollow shaft A1 0000-346-699 approx. 0.42 kg Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. Start-up and recommissioning (>>> 11.2.1 "Putting the cover for hollow shaft A1 into operation" Page 614) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 613/651 Options KR QUANTEC-2 Options KR QUANTEC-2 Maintenance (>>> 11.2.2 "Cleaning the cover of hollow shaft A1" Page 617) Disposal When the cover reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations or recycled. The following table provides an overview of the materials used. Plastics Aramid Textiles Polyamide Velcro fastener Natural rubber Elastic Metal PUR and aluminum 11.2.1 Textile coating Putting the cover for hollow shaft A1 into operation Description This section describes all work required to put the cover for hollow shaft A1 into operation. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench 5 Nm to 50 Nm - Material The following material is required: Designation Article number Quantity Cover on hollow shaft A1 0000-346-699 1 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot controller is switched off. • The robot is freely accessible. 614/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Installing the cover of hollow shaft A1 Options 11.2.1.1 Procedure 1. With energy supply system: Take off the support bracket of the energy supply system and mount the holder for the cover of hollow shaft A1 under the support bracket (>>> Fig. 11-6). 2. Place the holder for the cover of hollow shaft A1 on the rotating column. 3. Insert and tighten 2 M8x16-8.8 Allen screws. Increase the tightening torque to the specified value in several steps. Fig. 11-6: Mounting the bracket 1 Holder, cover on hollow shaft A1 2 M8x16-8.8-A2K Allen screw (2x) 4. Clamp the cover between the holder and the rotating column. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 615/651 Options KR QUANTEC-2 Fig. 11-7: Clamping the cover on hollow shaft A1 1 Cover on hollow shaft A1 2 Holder, cover on hollow shaft A1 5. With energy supply system: Take off bracket with Velcro fastener. 6. Pull the cover over the rotating column and close it under the counterbalancing system with the Velcro fastener and the press stud. Fig. 11-8: Pulling the cover over hollow shaft A1 and closing it 1 Outlet for energy supply system 2 Velcro fastener with press stud 3 Aperture for energy supply system bracket with Velcro fastener 7. With energy supply system: Mount the bracket with Velcro fastener on the rotating column. Insert and tighten 2 M8x16-8.8 Allen screws. Increase the tightening torque to the specified value in several stages. 616/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 8. Without energy supply system: Close outlet for energy supply system a using cable strap. Fig. 11-9: Closing the outlet 1 Outlet for energy supply system 2 Cable strap With energy supply system: Using the Velcro fastener, adapt the outlet for the energy supply system to the size of the cable bundle and close it as tightly as possible, but without crushing. 11.2.1.2 Concluding work The following concluding work must be carried out: • Carry out a test run in T1 mode and look out for irregularities. 11.2.2 Cleaning the cover of hollow shaft A1 Description The cover must be cleaned in compliance with the instructions given here in order to prevent damage. These instructions only refer to the cover. Equipment The following equipment is required: Designation Article number Permissible cleaning tools (e.g. cloths, brushes) - Material No material required. Precondition • The robot controller is switched off. • The robot is freely accessible. 11.2.2.1 Cleaning the cover of hollow shaft A1 Procedure 1. Take off the cover and clean it on all sides. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 617/651 Options KR QUANTEC-2 Options KR QUANTEC-2 NOTICE The textile is sensitive to humidity. Water and cleaning agents must not be used for cleaning. Damage to property may otherwise result. ‒ Remove dirt with a brush or dry cloth only. 2. Check holder for corrosion and apply corrosion protection if necessary. 3. Check cover for wear and damage and exchange if necessary. 4. Re-install the cover. 11.2.2.2 Concluding work The following concluding work must be carried out: • Remove cleaning agents and equipment from the workspace of the robot. • Dispose of cleaning agents in accordance with the pertinent regulations. • Replace any damaged or illegible plates and covers. • Install any safety equipment that has been removed and check that it is functioning correctly. Only a functional system with all safety functions may be put back into operation. 11.3 Cable set cover Description The cable set cover is a textile cover that is wrapped around the exposed parts of the cable set to protect it against heat radiation and dirt under particularly harsh conditions. 618/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Options KR QUANTEC-2 Fig. 11-10: Product overview 1 Cable set cover A3 2 Cable set cover A2 Basic data Designation Article number Weight Cover, cable set KR QUANTEC-2 0000-346-703 approx. 0.6 kg Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. Start-up and recommissioning (>>> 11.2.1 "Putting the cover for hollow shaft A1 into operation" Page 614) Maintenance (>>> 11.3.2 "Cleaning the cover of hollow shaft A1" Page 624) Disposal When the cover reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations or recycled. The following table provides an overview of the materials used. Plastics Aramid Textiles Polyamide Velcro fastener MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 619/651 Options KR QUANTEC-2 Natural rubber Elastic Metal PUR and aluminum 11.3.1 Textile coating Starting up the cable set cover Description This section describes all work required to put the cable set cover into operation. Equipment The following equipment is required: Designation Article number - - Material The following material is required: Designation Article number Quantity Cover, cable set KR QUANTEC-2 0000-346-703 1 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot controller is switched off. • The robot is freely accessible. 11.3.1.1 Installing the cable set cover Procedure 1. Fit cable set cover A1 around the cable set and position the apertures around the support brackets. 620/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Options KR QUANTEC-2 Fig. 11-11: Cable set cover A1 1 Apertures for support brackets 2 Cable set cover A1 0000-339-360 2. Insert the ends of the cover into the rotating column and link arm. 3. Close the Velcro fastener. There is no aperture for the support bracket on the side. Fig. 11-12: Velcro fastener 4. Fit the “cable set cover, bend A3” around the cable set and position the apertures around the support brackets. Fig. 11-13: Cable set cover, bend A3 1 Aperture for support bracket 2 Cable set cover, bend A3 0000-339-361 5. Insert one end into the link arm. 6. Close the Velcro fastener until approx. 30 cm in front of the motors. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 621/651 Options KR QUANTEC-2 Fig. 11-14: Velcro fastener 7. Fit cable set cover A4/A5 around the cable set and position the apertures around the connectors and support brackets. Fig. 11-15: Cable set cover A4/A5 1 Motor A4 2 Motor A5 3 Velcro fastener 4 Cable set cover A4/A5 0000-339-364 5 Aperture for support bracket 8. Close the Velcro fastener. 9. Fit the cable set cover A6 around the cable set and close the Velcro fastener. Fig. 11-16: Cable set cover A6 1 Cable set cover A3/A6 0000-339-363 10. Fit the “cable set cover, motor A3” around the cable set and close the Velcro fastener. 622/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Options KR QUANTEC-2 Fig. 11-17: Cable set cover A3 1 Cable set cover A3/A6 0000-339-363 2 Aperture for support bracket 3 Cable set cover, bend A3 0000-339-361 4 Cable set cover A3/A6 0000-339-363 11. Fit the cable strap around the cable set as illustrated and fasten it. Fig. 11-18: Cable strap 1 Cable set cover A3/A6 0000-339-363 2 Cable strap 3 Cable set cover, bend A3 0000-339-361 4 Cable set cover A3/A6 0000-339-363 NOTICE Wear due to friction The cover must not restrict the motions of the cable set. Premature wear may result. • During a test run, ensure that the cable set can move freely. • If necessary, open the Velcro fastener and close it again loosely. • Do not attach cable straps in the area of axis A2. • In the area of axis A3, attach cable straps only at the specified position. Do not secure anything else in the dynamic area of the cable set. 11.3.1.2 Concluding work The following concluding work must be carried out: • Carry out a test run in T1 mode and look out for irregularities. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 623/651 Options KR QUANTEC-2 NOTICE Wear due to friction The cover must not restrict the motions of the cable set. Premature wear may result. • During a test run, ensure that the cable set can move freely. • If necessary, open the Velcro fastener and close it again loosely. • Do not attach cable straps in the area of axis A2. • In the area of axis A3, attach cable straps only at the specified position. Do not secure anything else in the dynamic area of the cable set. 11.3.2 Cleaning the cover of hollow shaft A1 Description The cover must be cleaned in compliance with the instructions given here in order to prevent damage. These instructions only refer to the cover. Equipment The following equipment is required: Designation Article number Permissible cleaning tools (e.g. cloths, brushes) - Material No material required. Precondition • The robot controller is switched off. • The robot is freely accessible. 11.3.2.1 Cleaning the cover of hollow shaft A1 Procedure 1. Take off the cover and clean it on all sides. NOTICE The textile is sensitive to humidity. Water and cleaning agents must not be used for cleaning. Damage to property may otherwise result. ‒ Remove dirt with a brush or dry cloth only. 2. Check holder for corrosion and apply corrosion protection if necessary. 3. Check cover for wear and damage and exchange if necessary. 4. Re-install the cover. 11.3.2.2 Concluding work The following concluding work must be carried out: • Remove cleaning agents and equipment from the workspace of the robot. 624/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 • Dispose of cleaning agents in accordance with the pertinent regulations. • Replace any damaged or illegible plates and covers. • Install any safety equipment that has been removed and check that it is functioning correctly. Only a functional system with all safety functions may be put back into operation. 11.4 Purge option A Description Compressed air preparation system PURGE option A consists of a service unit and a pressure regulator unit. The service unit prepares the compressed air so that it contains no dirt particles, water or chemical contamination. The pressure regulator unit limits the operating pressure of the system and compensates for pressure fluctuations. A compressed air supply with 1 to 12 bar can be connected to the service unit. The compressed air preparation system is not suitable for installation in a hygiene area. Fig. 11-19: PURGE option A 1 Service unit 3 Pressure regulator unit 2 Compressed air hose 4 Holder Basic data Designation Article number Weight PURGE option A 0000-349-078 approx. 5.1 kg Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 625/651 Options KR QUANTEC-2 Options KR QUANTEC-2 Input pressure 0.1 - 1.2 MPa (1 - 12 bar) Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar) Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar) Maintenance If used for its intended purpose, the option requires minimal maintenance, i.e. visual inspections are recommended. In certain operating conditions, regular visual inspections may allow timely detection of changes. The nature and scope of the maintenance work depend very much on the specific area of application. This enables early detection of damage, thereby preventing failure of components and assemblies. Exchange damaged components or assemblies. Disposal When the option reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations and, where possible, separated and sorted for recycling. 11.5 Purge option B Description Compressed air preparation system PURGE option B consists of a pressure regulator unit that limits the operating pressure of the system and compensates for pressure fluctuations. The compressed air preparation system is not suitable for installation in a hygiene area. Fig. 11-20: PURGE option B 1 Compressed air hose 2 Pressure regulator unit 3 Holder Basic data Designation Article number Weight PURGE option B 0000-349-079 approx. 1.7 kg Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. 626/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Input pressure 0.1 - 1.2 MPa (1 - 12 bar) Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar) Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar) Maintenance If used for its intended purpose, the option requires minimal maintenance, i.e. visual inspections are recommended. In certain operating conditions, regular visual inspections may allow timely detection of changes. The nature and scope of the maintenance work depend very much on the specific area of application. This enables early detection of damage, thereby preventing failure of components and assemblies. Exchange damaged components or assemblies. Disposal When the option reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations and, where possible, separated and sorted for recycling. 11.6 Purge option C Description The functional principle of compressed air preparation system PURGE option C corresponds to that of PURGE option A. It is additionally equipped with a holder for installation on the base frame. The option consists of a service unit and a pressure regulator unit. The service unit prepares the compressed air so that it contains no dirt particles, water or chemical contamination. The pressure regulator unit limits the operating pressure of the system and compensates for pressure fluctuations. A compressed air supply with 1 to 12 bar can be connected to the service unit. The compressed air preparation system is not suitable for installation in a hygiene area. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 627/651 Options KR QUANTEC-2 Options KR QUANTEC-2 Fig. 11-21: PURGE option C 1 Holder 3 Pressure regulator unit 2 Service unit 4 Compressed air hose Basic data Designation Article number Weight PURGE option C 0000-349-102 approx. 5.9 kg Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Input pressure 0.1 - 1.2 MPa (1 - 12 bar) Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar) Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar) Start-up and recommissioning (>>> 11.6.1 "Starting up PURGE option C" Page 629) Maintenance If used for its intended purpose, the option requires minimal maintenance, i.e. visual inspections are recommended. In certain operating conditions, regular visual inspections may allow timely detection of changes. The nature and scope of the maintenance work depend very much on the specific area of application. This enables early detection of damage, thereby preventing failure of components and assemblies. Exchange damaged components or assemblies. Disposal When the option reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations and, where possible, separated and sorted for recycling. 628/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 11.6.1 Options KR QUANTEC-2 Starting up PURGE option C Description The PURGE option can be used to prepare compressed air for cleaning purposes. This section describes all work required to put PURGE option C into operation. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench 5 Nm to 50 Nm - Material The following material is required: Designation Article number Quantity PURGE option C 0000-349-102 1 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot controller is switched off. • The robot is freely accessible. Work safety SAFETY INSTRUCTION The following procedure must be followed exactly! WARNING Use of the option PURGE is limited to cleaning work. Use during running operation is precluded in order to prevent the emission of foreign particles. 11.6.1.1 Installing PURGE option C Procedure 1. Unscrew the 2 left-hand M8x20-8.8 Allen screws from the cover plate (>>> Fig. 11-22). MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 629/651 Options KR QUANTEC-2 2. Position the holder on the base frame, insert 2 M8x20-8.8 Allen screws and conical spring washers and tighten them. Increase the tightening torque to the specified value in several stages. 3. Connect compressed air hose to interface A1. Fig. 11-22: Installing PURGE option C 1 M8x20-8.8-A2K Allen screw (2x) with conical spring washer 2 Holder 3 Service unit 4 Pressure regulator unit 5 Compressed air hose 11.6.1.2 Concluding work The following concluding work must be carried out: • Carry out a test run in T1 mode and look out for irregularities. 11.7 Purge option D Description The functional principle of compressed air preparation system PURGE option D corresponds to that of PURGE option B. It is additionally equipped with a holder for installation on the base frame. The option consists of a pressure regulator unit that limits the operating pressure of the system and compensates for pressure fluctuations. The compressed air preparation system is not suitable for installation in a hygiene area. 630/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Options KR QUANTEC-2 Fig. 11-23: PURGE option D 1 Holder 2 Pressure regulator unit 3 Compressed air hose Basic data Designation Article number Weight PURGE option D 0000-349-103 approx. 2.4 kg Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. Operating pressure (PURGE) max. 0.03 MPa (0.3 bar) ±10% Air consumption 0.1 m3/h Air line connection Push-in fitting for hose, 6 mm Input pressure 0.1 - 1.2 MPa (1 - 12 bar) Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar) Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar) Start-up and recommissioning (>>> 11.7.1 "Starting up PURGE option D" Page 632) Maintenance If used for its intended purpose, the option requires minimal maintenance, i.e. visual inspections are recommended. In certain operating conditions, regular visual inspections may allow timely detection of changes. The nature and scope of the maintenance work depend very much on the specific area of application. This enables early detection of damage, thereby preventing failure of components and assemblies. Exchange damaged components or assemblies. Disposal When the option reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations and, where possible, separated and sorted for recycling. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 631/651 Options KR QUANTEC-2 11.7.1 Starting up PURGE option D Description The PURGE option can be used to prepare compressed air for cleaning purposes. This section describes all work required to put PURGE option D into operation. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench 5 Nm to 50 Nm - Material The following material is required: Designation Article number Quantity PURGE option D 0000-349-103 1 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 635) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The robot controller is switched off. • The robot is freely accessible. Work safety SAFETY INSTRUCTION The following procedure must be followed exactly! WARNING Use of the option PURGE is limited to cleaning work. Use during running operation is precluded in order to prevent the emission of foreign particles. 11.7.1.1 Installing PURGE option D Procedure 1. Unscrew the 2 left-hand M8x20-8.8 Allen screws from the cover plate (>>> Fig. 11-24). 632/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 2. Position the holder on the base frame, insert 2 M8x20-8.8 Allen screws and conical spring washers and tighten them. Increase the tightening torque to the specified value in several stages. 3. Connect compressed air hose to interface A1. Fig. 11-24: Installing PURGE option D 1 M8x20-8.8-A2K Allen screw (2x) with conical spring washer 2 Holder 3 Pressure regulator unit 4 Compressed air hose 11.7.1.2 Concluding work The following concluding work must be carried out: • Carry out a test run in T1 mode and look out for irregularities. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 633/651 Options KR QUANTEC-2 Options KR QUANTEC-2 634/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 12 Appendix 12.1 Tightening torques Appendix KR QUANTEC-2 Tightening torques The following tightening torques (Nm) are valid for screws and nuts where no other specifications are given. The specified values apply to lightly oiled black (e.g. phosphated) and coated (e.g. mech. galv., zinc flake plating, screw locking elements) screws and nuts. Strength class Thread 8.8 10.9 12.9 M1.6 0.17 Nm 0.24 Nm 0.28 Nm M2 0.35 Nm 0.48 Nm 0.56 Nm M2.5 0.68 Nm 0.93 Nm 1.10 Nm M3 1.2 Nm 1.6 Nm 2.0 Nm M4 2.8 Nm 3.8 Nm 4.4 Nm M5 5.6 Nm 7.5 Nm 9.0 Nm M6 9.5 Nm 12.5 Nm 15.0 Nm M8 23.0 Nm 31.0 Nm 36.0 Nm M10 45.0 Nm 60.0 Nm 70.0 Nm M12 78.0 Nm 104.0 Nm 125.0 Nm M14 125.0 Nm 165.0 Nm 195.0 Nm M16 195.0 Nm 250.0 Nm 305.0 Nm M20 370.0 Nm 500.0 Nm 600.0 Nm M24 640.0 Nm 860.0 Nm 1030.0 Nm M30 1330.0 Nm 1700.0 Nm 2000.0 Nm Strength class Thread 8.8 ISO7991 Allen screw 10.9 ISO7380, ISO07381 Fillister head screw M3 0.8 Nm 0.8 Nm M4 1.9 Nm 1.9 Nm M5 3.8 Nm 3.8 Nm Strength class Thread 10.9 DIN7984 Pan head screws M4 2.8 Nm Tighten M5 domed cap nuts with a torque of 4.2 Nm. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 635/651 Appendix KR QUANTEC-2 12.2 Auxiliary and operating materials used Product designation / Article number Use Manufacturer designation / Address Castrol Hyspin ZZ 46 Hydraulic oil Deutsche Castrol Vertriebsgesellschaft mbH Max-Born-Str. 2 D-22761 Hamburg Germany Surface sealant Drei Bond GmbH Carl-Zeiss-Ring 13 D-85737 Ismaning Germany Adhesive and sealant Drei Bond GmbH Carl-Zeiss-Ring 13 D-85737 Ismaning Germany Adhesive and sealant Drei Bond GmbH Carl-Zeiss-Ring 13 D-85737 Ismaning Germany Adhesive and sealant Drei Bond GmbH Carl-Zeiss-Ring 13 D-85737 Ismaning Germany Lubricating grease SKF Maintenance Products Postboks 1008 NL-3430 BA Nieuwegein Netherlands Lubricant ExxonMobil Petroleum & Chemical BVBA POLDERDIJKWEG B-2030 Antwerp Belgium Lubricating grease Klüber Lubrication München KG Geisenhausenerstr. 7 D-81379 Munich Germany 0083-236-203 Drei Bond type 1118 0000-265-996 Drei Bond type 1305 0000-184-175 Drei Bond type 1342 0000-184-174 Drei Bond type 5204HV 0000-251-505 LGEP 2 0000-119-990 MARCOL 82 0000-386-390 Microlube GL 261 0000-135-463 636/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Optigear Synt. ALR 150_EEA Gear oil BP Europa SE Geschäftsbereich Industrieschmierstoffe Erkelenzer Strasse 20 D-41179 Mönchengladbach Germany Lubricating grease Deutsche BP Aktiengesellschaft - Industrial Lubricants & Services Erkelenzer Strasse 20 D-41179 Mönchengladbach Germany Lubricating grease Klüber Lubrication München KG Geisenhausenerstr. 7 D-81379 Munich Germany 0000-362-835 for European Economic Area Optigear Synt. ALR 150_AM1 0000-361-461 for USA, Canada, Mexico, Chile, Peru Optigear Synt. ALR 150_CHN 0000-361-473 for China Optigear Synt. ALR 150_APeC1 0000-361-476 for India, Taiwan, Japan, Thailand, South Korea, Malaysia Article numbers for further regions can be found in KUKA Xpert. Optitemp RB 2 0000-101-456 PETAMO GHY 133 N 0000-269-159 To ensure safe use of our products, we recommend regularly requesting up-to-date safety data sheets from the manufacturers of auxiliary and operating materials. 12.3 Information sheet for products Section 1 Designation of the product and of the company • Product identifier: ‒ Trade name: KUKA industrial robot with hydropneumatic counterbalancing system • Relevant identified use of the product that is advised against: No further relevant information available. • Use of the product: Robot for industrial use • Details of the supplier providing the information sheet: MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 637/651 Appendix KR QUANTEC-2 Appendix KR QUANTEC-2 Manufacturer/supplier: KUKA Deutschland GmbH Address Zugspitzstrasse 140 Postal code D‑86165 Augsburg Country Germany Phone: +49 821 797 4000 Fax: +49 821 797 40400 e-mail info@kuka.com Right of access KUKA Deutschland GmbH Quality Assurance department +49 821 797 1747 Information in case of emergency During normal operating hours +49 821 797 1747 • Note on the information sheet for products: There is no legal obligation to create a safety data sheet for a product. In order to make information typically contained in a safety data sheet available for products, however, the present “Information Sheet for Products” was created. Your attention is expressly drawn to the fact that the information sheet for products is an information sheet created voluntarily that is not subject to the formal requirements of Regulation (EC) No. 1907/2006 (REACH Regulation). Section 2 Possible hazards • Classification of the substance or mixture: • • • • ‒ Classification acc. to Regulation (EC) No. 1272/2008 (CLP Regulation): This product is not classified according to the CLP Regulation. Classification acc. to Directive 67/548/EEC or Directive 1999/45/EC: Not applicable Particular safety warnings for persons and the environment: Not applicable Classification system: Not applicable Label elements Labeling acc. to Reg- Not applicable ulation (EC) No. 1272/2008 (CLP Regulation): Hazard symbol: Not applicable Signal word: Not applicable Hazard statements: Not applicable • Other hazards ‒ Results of PBT and vPvB assessment 638/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 PBT Not applicable vPvB Not applicable Appendix KR QUANTEC-2 Section 3 Composition / information about the components • Chemical characterization: Mixtures ‒ Description: Robot for industrial use • Hazardous components: The robot is equipped with a counterbalancing system, filled with nitrogen. CAS: 7727‑37‑9 Nitrogen Press. Gas, H281 EINECS: 231‑783‑9 The exact wording of the hazard statements listed above can be found in section 16 (>>> "Section 16" Page 643). Section 4 First aid measures • Description of first aid measures: ‒ General information: No special measures required. • Most important symptoms and effects, both acute and delayed: No further relevant information available. • Indication of any immediate medical attention and special treatment needed: No further relevant information available. Section 5 Fire-fighting measures • Extinguishing agents: Suitable extinguishing agents: Adjust the fire-extinguishing measures to suit the environment. • Special hazards arising from the substance or mixture: No further relevant information available. • Advice for firefighters: ‒ Special protective equipment: No special measures required. Section 6 Measures after unintended release MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 639/651 Appendix KR QUANTEC-2 • Personal precautions, protective equipment and emergency procedures: Not required • Environmental protection measures: No special measures required. • Methods and material for containment and cleaning up: No special measures required. • Reference to other sections For information on safe handling, see section 7 (>>> "Section 7" Page 640). For information on personal protective equipment, see section 8 (>>> "Section 8" Page 640). For information on disposal, see section 13 (>>> "Section 13" Page 642). Section 7 Handling and storage • Precautions for safe handling: No special measures required. • Instructions relating to fire and explosion protection: No special measures required. • Conditions for safe storage, including any incompatibilities: ‒ Storage Requirements regarding storage rooms and containers: No special requirements Information on stor- Not required age with other products: Further specifications concerning storage conditions: None • Specific end uses: No further relevant information available. Section 8 Limitation and monitoring of exposure / Personal protective equipment • Additional information for the design of technical systems: No further specifications, see section 7 (>>> "Section 7" Page 640). • Control parameters Components with applicable occupational exposure limit values: The product contains no relevant amounts of materials that are subject to monitoring of limit values in the workplace. • Limitation and monitoring of exposure: ‒ Personal protective equipment: 640/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Respiratory protection: Not required Hand protection: Chemical protective gloves are not required. Eye protection: Not required Section 9 Physical and chemical properties • Information on basic physical and chemical properties: ‒ General information Form: Solid Color: As per product description Odor: Odorless Melting point/range: Not determined Flash point: Not applicable Auto-ignition: The product does not auto-ignite. Risk of explosion: The product presents no danger of explosion. Density: Not determined Solubility/miscibility in water: Insoluble Additional information: No further information available. Section 10 Stability and reactivity • Possibility of hazardous reactions: No hazardous reactions known. • Conditions to be avoided No relevant information available. • Incompatible materials No further relevant information available. • Hazardous decomposition products No hazardous decomposition products known. Section 11 Toxicological information • Information on toxicological effects: ‒ Acute toxicity: Primary irritation effect on skin: No irritation Primary irritation effect on eyes: No irritation Sensitization: No sensitizing effect known. MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 641/651 Appendix KR QUANTEC-2 Appendix KR QUANTEC-2 Additional toxicologi- The product is not subject to labeling oblical information: gations due to the method of calculation in the latest version of the “EC General Classification Directive for Preparations”. Section 12 Ecological information • Toxicity: Aquatic toxicity: No further relevant information available. • Persistence and degradability: No further relevant information available. • Bioaccumulative potential: No further relevant information available. • Mobility in soil: No further relevant information available. • Additional ecological information: General information: No known hazard to water. • Results of PBT and vPvB assessment: PBT Not applicable vPvB Not applicable • Other adverse effects: No further relevant information available. Section 13 Disposal information • Waste treatment methods: Recommendation: Speak with manufacturer regarding recycling. • Contaminated packaging: Recommendation: Disposal in accordance with the applicable regulations. Section 14 Transport information • UN number ‒ ADR, RID, ADN: Not subject to the provisions (transitional provision 1.6.1.46) ‒ IMDG code, IATA: UN 3164 • UN proper shipping name: ‒ IMDG code, IATA: ARTICLES, PRESSURIZED, HYDRAULIC (containing non-flammable gas) • Transport hazard classes: ‒ ADR, RID, ADN: Not applicable (transitional provision 1.6.1.46) ‒ IMDG code: 642/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Appendix KR QUANTEC-2 Class: 2.2 Non-flammable, non-toxic gas Hazard label: 2.2 Marine pollutants: No EmS number: F-C, S-V Shipping: P003, PP32 ‒ IATA: Class: 2.2 Non-flammable, non-toxic gas Hazard label: - Shipping: Packaging instructions 208 (a) • Packaging group: Not applicable • UN “Model Regulation”: UN 3164 ARTICLES, PRESSURIZED, HYDRAULIC, 2.2 NOTE: Detailed information on the amount of nitrogen contained for each KUKA industrial robot with a hydropneumatic counterbalancing system is available at https://xpert.kuka.com. NOTE: Robots with counterbalancing systems that are not filled with nitrogen are not subject to the regulations on dangerous goods! Section 15 Regulatory information • Chemical safety assessment: Chemical safety assessment has not been performed. Section 16 Other information The information given is based on our present knowledge. However, this shall not constitute a guarantee for any specific product characteristics and shall not establish a legally valid contractual relationship. • Relevant phrases: H281: Contains refrigerated gas; may cause cryogenic burns or injury 12.4 Applied standards and regulations Name/Edition Definition 2006/42/EC Machinery Directive: Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast) MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 643/651 Appendix KR QUANTEC-2 2014/30/EU EMC Directive: Directive 2014/30/EU of the European Parliament and of the Council dated 26 February 2014 on the approximation of the laws of the Member States concerning electromagnetic compatibility 2014/68/EU Pressure Equipment Directive: Directive 2014/68/EU of the European Parliament and of the Council dated 15 May 2014 on the approximation of the laws of the Member States concerning pressure equipment (Only applicable for robots with hydropneumatic counterbalancing system.) ANSI/RIA R15.06-2012 Industrial Robots and Robot System EN 60204-1:2018 Safety of machinery: Electrical equipment of machines – Part 1: General requirements EN 61000-6-2:2005 Electromagnetic compatibility (EMC): Part 6-2: Generic standards; Immunity for industrial environments EN 61000-6-4:2007 + A1:2011 EN 614-1:2006+A1:2009 Electromagnetic compatibility (EMC): Part 6-4: Generic standards; Emission standard for industrial environments Safety of machinery: Ergonomic design principles - Part 1: Terms and general principles EN IEC 61000-6-2:2019 Electromagnetic compatibility (EMC): Part 6-2: Generic standards – Immunity for industrial environments EN IEC 61000-6-4:2019 Electromagnetic compatibility (EMC): Part 6-4: Generic standards; Emission standard for industrial environments EN ISO 10218-1:2011 Robots and robotic devices – Safety requirements for industrial robots: Part 1: Robots EN ISO 12100:2010 Safety of machinery: General principles of design, risk assessment and risk reduction EN ISO 13849-1:2015 Safety of machinery: Safety-related parts of control systems - Part 1: General principles of design EN ISO 13849-2:2012 Safety of machinery: Safety-related parts of control systems - Part 2: Validation EN ISO 13850:2015 Safety of machinery: Emergency stop - Principles for design 644/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 13 KUKA Service 13.1 Requesting support KUKA Service KR QUANTEC-2 Introduction This documentation provides information on operation and operator control, and provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary. Information The following information is required for processing a support request: • Description of the problem, including information about the duration and frequency of the fault • The greatest possible amount of information about the hardware and software components of the overall system The following list gives an indication of the information which is relevant in many cases: ‒ Model and serial number of the kinematic system, e.g. the manipulator ‒ Model and serial number of the controller ‒ Model and serial number of the energy supply system ‒ Designation and version of the system software ‒ Designations and versions of other software components or modifications ‒ System software diagnosis package Additionally for KUKA Sunrise: Existing projects including applications For versions of KUKA System Software older than V8: Archive of the software (Diagnosis package is not yet available here.) ‒ Application used ‒ External axes used 13.2 KUKA Customer Support The contact details of the local subsidiaries can be found at: www.kuka.com/customer-service-contacts MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 645/651 KUKA Service KR QUANTEC-2 646/651 | www.kuka.com MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Index 2006/42/EC................................................... 643 2014/30/EU................................................... 644 2014/68/EU................................................... 644 95/16/EC....................................................... 643 A Accessories.....................................................25 Angle of rotation............................................. 15 ANSI/RIA R15.06-2012................................ 644 Appendix....................................................... 635 Arctic............................................................... 14 Arm................................................................. 21 Automatic mode..............................................36 Auxiliary materials used............................... 636 Axis data, KR 120 R2700-2...........................45 Axis data, KR 120 R2700-2 F....................... 58 Axis data, KR 120 R3100-2...........................71 Axis data, KR 120 R3100-2 F....................... 83 Axis data, KR 150 R2700-2...........................95 Axis data, KR 150 R2700-2 F..................... 108 Axis data, KR 150 R3100-2.........................121 Axis data, KR 150 R3100-2 F..................... 133 Axis data, KR 180 R2900-2.........................145 Axis data, KR 180 R2900-2 F..................... 158 Axis data, KR 210 R2700-2.........................171 Axis data, KR 210 R2700-2 F..................... 184 Axis data, KR 210 R3100-2.........................197 Axis data, KR 210 R3100-2 C.....................221 Axis data, KR 210 R3100-2 F..................... 209 Axis data, KR 240 R2900-2.........................233 Axis data, KR 240 R2900-2 C.....................259 Axis data, KR 240 R2900-2 F..................... 246 Axis data, KR 250 R2700-2.........................272 Axis data, KR 250 R2700-2 C.....................298 Axis data, KR 250 R2700-2 F..................... 285 Axis data, KR 300 R2700-2.........................311 Axis data, KR 300 R2700-2 C.....................337 Axis data, KR 300 R2700-2 F..................... 324 Axis limitation, mechanical............................. 30 Axis range................................................ 14, 26 B Base frame..................................................... 22 Basic data, KR 120 R2700-2.........................43 Basic data, KR 120 R2700-2 F..................... 56 Basic data, KR 120 R3100-2.........................69 Basic data, KR 120 R3100-2 F..................... 81 Basic data, KR 150 R2700-2.........................93 Basic data, KR 150 R2700-2 F................... 106 Basic data, KR 150 R3100-2.......................119 Basic data, KR 150 R3100-2 F................... 131 Basic data, KR 180 R2900-2.......................143 Basic data, KR 180 R2900-2 F................... 156 Basic data, KR 210 R2700-2.......................169 Basic data, KR 210 R2700-2 F................... 182 Basic data, KR 210 R3100-2.......................195 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Basic data, KR 210 R3100-2 C...................219 Basic data, KR 210 R3100-2 F................... 207 Basic data, KR 240 R2900-2.......................231 Basic data, KR 240 R2900-2 C...................257 Basic data, KR 240 R2900-2 F................... 244 Basic data, KR 250 R2700-2.......................270 Basic data, KR 250 R2700-2 C...................296 Basic data, KR 250 R2700-2 F................... 283 Basic data, KR 300 R2700-2.......................309 Basic data, KR 300 R2700-2 C...................335 Basic data, KR 300 R2700-2 F................... 322 Brake defect................................................... 31 Brake release device......................................30 Braking distance.......................................14, 26 C C..................................................................... 14 Cable set cover............................................ 618 Installation................................................620 Start-up.................................................... 620 Castrol Hyspin ZZ 46...................................636 CE mark..........................................................26 Center of gravity...........................................427 Center of mass .. 48, 61, 74, 86, 98, 111, 124, 136, 148, 161, 174, 187, 200, 212, 224, 236, 249, 262, 275, 288, 301, 314, 327, 340 Certificates....45, 71, 95, 121, 145, 171, 197, 233, 272, 311 Clean Room....................................................14 Cleaning the robot........................................507 Cleaning work.................................................37 Connecting cable, standard.................448, 452 Connecting cables.. 25, 44, 58, 70, 71, 83, 94, 95, 108, 120, 121, 133, 144, 145, 158, 170, 171, 184, 196, 197, 209, 220, 221, 232, 233, 246, 258, 259, 271, 272, 285, 297, 298, 310, 311, 324, 336, 337, 423 Connecting shafts, exchanging.................... 579 Counterbalancing system.........................22, 37 Counterbalancing system, checking... 485, 486, 497, 506 Counterbalancing system, hydropneumatic... 22 Counterbalancing system, installing, ceilingmounted robot.............................................. 503 Counterbalancing system, removal, ceilingmounted robot.............................................. 500 Cover for hollow shaft A1 Putting into operation.............................. 614 Cover of hollow shaft A1............................. 613 Cover of hollow shaft A1, cleaning..... 617, 624 CR...................................................................14 D Danger zone.............................................15, 27 Declaration of conformity............................... 26 Declaration of incorporation.....................25, 26 Decommissioning................................... 38, 601 Description of the robot system.....................19 www.kuka.com | 647/651 KR QUANTEC-2 Diagnosis package....................................... 645 Dimensions, transportation...........................427 Directives...................................................... 643 Disclaimer....................................................... 25 Disposal......................................... 38, 601, 607 Documentation, industrial robot..................... 13 Drei Bond type 1118.................................... 636 Drei Bond type 1305....................................636 Drei Bond type 1342....................................636 Drei Bond type 5204HV...............................636 E EC declaration of conformity......................... 26 EDS.................................................................14 EDS cool.........................................................14 Electrical installations.............................22, 589 Electromagnetic compatibility (EMC)........... 644 Electromagnetic compatibility (EMC):.......... 644 EMC Directive........................................ 26, 644 EMD................................................................ 15 EN 60204-1:2018......................................... 644 EN 61000-6-2:2005...................................... 644 EN 61000-6-4:2007 + A1:2011.................... 644 EN 61000-6-4:2019...................................... 644 EN 614-1:2006+A1:2009..............................644 EN IEC 61000-6-2:2019...............................644 EN ISO 10218-1:2011.................................. 644 EN ISO 12100:2010..................................... 644 EN ISO 13849-1:2015..................................644 EN ISO 13849-2:2012..................................644 EN ISO 13850:2015..................................... 644 Equipment securing the link arm, removing...................................... 496, 505, 521 Equipment securing the robot arm, removing....................................................... 531 ESD.45, 71, 95, 121, 145, 171, 197, 233, 272, 311 EX................................................................... 15 Extension........................................................ 14 External axes..................................................25 External axis.............................................17, 28 F F......................................................................15 F exclusive......................................................15 Faults.............................................................. 33 Flange loads....51, 64, 76, 88, 101, 114, 126, 138, 151, 164, 177, 190, 202, 214, 226, 239, 252, 265, 278, 291, 304, 317, 330, 343 Fork lift truck.................................................429 Foundation loads, KR 120 R2700-2..............54 Foundation loads, KR 120 R2700-2 F.......... 67 Foundation loads, KR 120 R3100-2..............79 Foundation loads, KR 120 R3100-2 F.......... 91 Foundation loads, KR 150 R2700-2............104 Foundation loads, KR 150 R2700-2 F........ 117 Foundation loads, KR 150 R3100-2............129 Foundation loads, KR 150 R3100-2 F........ 141 648/651 | www.kuka.com Foundation loads, KR 180 R2900-2............154 Foundation loads, KR 180 R2900-2 F........ 167 Foundation loads, KR 210 R2700-2............180 Foundation loads, KR 210 R2700-2 F........ 193 Foundation loads, KR 210 R3100-2............205 Foundation loads, KR 210 R3100-2 C........229 Foundation loads, KR 210 R3100-2 F........ 217 Foundation loads, KR 240 R2900-2............242 Foundation loads, KR 240 R2900-2 C........268 Foundation loads, KR 240 R2900-2 F........ 255 Foundation loads, KR 250 R2700-2............281 Foundation loads, KR 250 R2700-2 C........307 Foundation loads, KR 250 R2700-2 F........ 294 Foundation loads, KR 300 R2700-2............320 Foundation loads, KR 300 R2700-2 C........346 Foundation loads, KR 300 R2700-2 F........ 333 Foundry robots....57, 82, 107, 132, 157, 183, 208, 245, 284, 323 Foundry, equipment....57, 82, 107, 132, 157, 183, 208, 245, 284, 323 Function test................................................... 34 G Gear oil A1, draining....................................466 Gear unit A1, filling with oil......................... 467 Gear unit A3, draining oil.............................474 Gear unit A3, filling with oil......................... 475 Gear unit A4, draining oil.............................478 Gear unit A4, filling with oil......................... 479 Gear unit A5/A6, draining oil...............482, 484 General safety measures............................... 31 Ground conductor................................ 451, 455 H HA................................................................... 15 Handling equipment............ 429, 435, 440, 444 Hazardous substances................................... 38 HI.................................................................... 15 HM.................................................................. 15 HO...................................................................15 HP................................................................... 15 HW.................................................................. 15 I In-line wrist..................................................... 21 Industrial robot................................................25 Industrial Robots and Robot System...........644 Information for planning............................... 415 Information sheet for products.....................637 Interface A1.................................................. 424 Interface, connecting cables................448, 451 Interface, energy supply system..................425 Interfaces...................................................... 423 Introduction..................................................... 13 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 K K......................................................................15 KCP....................................................15, 27, 32 Keyboard, external......................................... 32 KR................................................................... 15 KR C............................................................... 15 KS................................................................... 15 KUKA Customer Support............................. 645 KUKA Service...............................................645 KUKA smartPAD...................................... 15, 27 KUKA smartPAD-2................................... 15, 27 L Labeling.......................................................... 31 LGEP 2......................................................... 636 Lifting tackle..................................................430 Lifting tackle (optional)................................. 429 Linear unit.......................................................25 Link arm..........................................................21 Link arm, securing.......................489, 500, 517 Low Voltage Directive.....................................26 M Machine frame mounting..............................421 Machinery Directive................................26, 643 Main axes..................................................... 352 Maintenance........................................... 36, 457 Maintenance symbols...................................458 Manipulator..................................15, 20, 25, 27 Manual mode..................................................35 MARCOL 82................................................. 636 Mass... 48, 61, 74, 86, 98, 111, 124, 136, 148, 161, 174, 187, 200, 212, 224, 236, 249, 262, 275, 288, 301, 314, 327, 340 Mass moments of inertia....49, 62, 74, 86, 99, 112, 124, 136, 149, 162, 175, 188, 200, 212, 225, 237, 250, 263, 276, 289, 302, 315, 328, 341 Material designation..................................... 607 Mechanical end stops.................................... 29 MEMD............................................................. 15 micro RDC...................................................... 15 Microlube GL 261.........................................636 Misuse.............................................................23 Motion velocity................................................16 Motor A1, exchanging.................................. 509 Motor A2, exchanging.................................. 514 Motor A3, exchanging.................................. 522 Motor A3, installing.......................................529 Motor A3, removing......................................526 Motor A4, exchanging.................................. 532 Motor A4, installing............. 537, 562, 577, 587 Motor A4, removing............ 535, 550, 566, 582 Motor A5, exchanging.................................. 539 Motor A5, installing............. 545, 560, 575, 585 Motor A5, removing............ 542, 552, 568, 583 Motor A6, exchanging.................................. 547 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 Motor A6, installing.............................. 557, 573 Motor A6, removing............................. 556, 572 Mounting base with centering............. 415, 418 Mounting flange...21, 50, 63, 76, 88, 100, 113, 126, 138, 150, 163, 176, 189, 202, 214, 226, 238, 251, 264, 277, 290, 303, 316, 329, 342 Mouse, external.............................................. 32 MT...................................................................15 N New in-line wrist, preparing......................... 572 New motor A4 - A5, preparing for installation............................................ 536, 544 New motor, preparing for installation...........556 O Oil change, A1..............................................461 Oil change, A1, ceiling-mounted robot........ 464 Oil change, A2..............................................468 Oil change, A3..............................................472 Oil change, A4..............................................476 Oil change, A5..............................................480 Oil temperatures........................................... 458 Operating materials used............................. 636 Operators........................................................ 29 Optigear Synt. ALR 150...............................637 Options.............................................22, 25, 609 Optitemp RB 2..............................................637 Overload......................................................... 31 P P......................................................................15 PA................................................................... 15 Payload diagram..49, 62, 75, 87, 99, 112, 125, 137, 149, 162, 175, 188, 201, 213, 225, 237, 250, 263, 276, 289, 302, 315, 328, 341 Payloads, KR 120 R2700-2........................... 48 Payloads, KR 120 R2700-2 F....................... 61 Payloads, KR 120 R3100-2........................... 73 Payloads, KR 120 R3100-2 F....................... 85 Payloads, KR 150 R2700-2........................... 98 Payloads, KR 150 R2700-2 F...................... 111 Payloads, KR 150 R3100-2......................... 123 Payloads, KR 150 R3100-2 F..................... 135 Payloads, KR 180 R2900-2......................... 148 Payloads, KR 180 R2900-2 F..................... 161 Payloads, KR 210 R2700-2......................... 174 Payloads, KR 210 R2700-2 F..................... 187 Payloads, KR 210 R3100-2......................... 199 Payloads, KR 210 R3100-2 C..................... 223 Payloads, KR 210 R3100-2 F......................211 Payloads, KR 240 R2900-2......................... 236 Payloads, KR 240 R2900-2 C..................... 262 Payloads, KR 240 R2900-2 F..................... 249 Payloads, KR 250 R2700-2......................... 275 Payloads, KR 250 R2700-2 C..................... 301 Payloads, KR 250 R2700-2 F..................... 288 www.kuka.com | 649/651 KR QUANTEC-2 Payloads, KR 300 R2700-2......................... 314 Payloads, KR 300 R2700-2 C..................... 340 Payloads, KR 300 R2700-2 F..................... 327 Personal protective equipment...................... 28 Personnel........................................................28 PETAMO GHY 133 N.................................. 637 Phi...................................................................15 Planning........................................................ 415 Plant integrator............................................... 27 Plates and labels..........................................348 Positioner........................................................ 25 POV................................................................ 16 PPE.................................................................28 Preparing for storage................................... 606 Pressure Equipment Directive.........22, 37, 644 Pressure regulator. 57, 82, 107, 132, 157, 183, 208, 245, 284, 323 Preventive maintenance work........................ 37 Product description.........................................19 Program override............................................16 Protective circuit............................................. 22 Protective equipment, overview..................... 29 Purge Option A.................................................. 625 Option B.................................................. 626 Option C.................................................. 627 Option D.................................................. 630 PURGE option C Start-up.................................................... 629 PURGE option D Start-up.................................................... 632 R RDC................................................................ 16 RDC cool........................................................ 16 Reaction distance.....................................14, 26 Recommissioning................................... 33, 433 Refilling quantity. 462, 465, 469, 473, 477, 481 Regulations................................................... 643 Release device.......................................30, 609 Start-up.................................................... 610 Repair..................................................... 36, 509 Robot arm, securing.....................................525 Robot controller.............................................. 25 Robot, removing........................................... 601 Rotating column..............................................22 S Safety..............................................................25 Safety instructions.......................................... 13 Safety of machinery..................................... 644 Safety zone.............................................. 27, 29 Safety, general................................................25 SC................................................................... 16 SE................................................................... 16 Securing loads..............................................431 Service life...................................................... 27 SI.....................................................................16 650/651 | www.kuka.com SL....................................................................16 smartPAD........................................... 16, 27, 32 Software..........................................................25 Spare parts....488, 499, 510, 516, 524, 533, 541, 549, 565, 581 SPP.................................................................15 Standards......................................................643 Start-up...................................................33, 433 Start-up, floor-mounted robots (mounting base).............................................................433 Start-up, floor-mounted robots (optional 150 mm mounting base)..............................438 Starting up robots (machine frame mounting)...................................................... 443 STOP 0.........................................................352 STOP 1.........................................................352 Stop categories........................................ 16, 27 Stop signal....................................................353 Stopping distance............................ 14, 26, 353 Stopping distances....352, 354, 359, 365, 371, 377, 383, 389, 395, 401, 407 Stopping time................................................353 Stopping times...352, 354, 359, 365, 371, 377, 383, 389, 395, 401, 407 Storage...........................................38, 601, 603 Supplementary load...52, 65, 77, 89, 102, 115, 127, 139, 152, 165, 178, 191, 203, 215, 227, 240, 253, 266, 279, 292, 305, 318, 331, 344 Support request............................................ 645 System integrator..................................... 26–28 T T1 (operating mode)................................ 16, 27 T2 (operating mode)................................ 16, 27 Teach pendant................................................ 25 Technical data.................................................39 Technical data, KR 120 R2700-2.................. 43 Technical data, KR 120 R2700-2 F...............56 Technical data, KR 120 R3100-2.................. 69 Technical data, KR 120 R3100-2 F...............81 Technical data, KR 150 R2700-2.................. 93 Technical data, KR 150 R2700-2 F.............106 Technical data, KR 150 R3100-2.................119 Technical data, KR 150 R3100-2 F.............131 Technical data, KR 180 R2900-2................ 143 Technical data, KR 180 R2900-2 F.............156 Technical data, KR 210 R2700-2................ 169 Technical data, KR 210 R2700-2 F.............182 Technical data, KR 210 R3100-2................ 195 Technical data, KR 210 R3100-2 C............ 219 Technical data, KR 210 R3100-2 F.............207 Technical data, KR 240 R2900-2................ 231 Technical data, KR 240 R2900-2 C............ 257 Technical data, KR 240 R2900-2 F.............244 Technical data, KR 250 R2700-2................ 270 Technical data, KR 250 R2700-2 C............ 296 Technical data, KR 250 R2700-2 F.............283 Technical data, KR 300 R2700-2................ 309 Technical data, KR 300 R2700-2 C............ 335 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 KR QUANTEC-2 Technical data, KR 300 R2700-2 F.............322 Technical data, overview................................ 39 Terms used..................................................... 14 Terms, safety.................................................. 26 Tightening torques........................................635 Training.......................................... 13, 457, 509 Transport position......................................... 427 Transport safeguard..................................... 431 Transportation........................................ 33, 427 Transportation by fork lift truck.................... 429 Transportation with lifting tackle.................. 430 Turn-tilt table...................................................25 U Use Intended..................................................... 23 User.......................................................... 26, 28 Users...............................................................13 W W.....................................................................16 Warnings......................................................... 13 Wiring diagrams, electrical installations.......591 Workspace......................................... 14, 26, 29 WP.................................................................. 16 MA KR QUANTEC-2 V11 | Issued: 21.08.2023 www.kuka.com | 651/651

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